iii Millerfi

iii Millerfi September 1991 FORM: OM-1584A

Effective With Serial No. KB1 231 43 I

MODEL: DS-12

DS-16

OWNER�S MANUAL

IMPORTANT: Read and understand the entire contents of both this manual

and the power source manual used with this unIt, with speclai emphasis on

the safety material throughout both manuals, before InstallIng, operating, or

maintaining this equipment. This unit and these instructions are for use onlyby persons trained and experienced in the safe operation of welding equipment. Do not allow untrained persons to install, operate, or maintain this unit.

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

MILLER ELECTRIC Mfg. Co.A Miller Group Ltd., Company

P.O. Box 1079

Appleton, WI 54912 USA

Tel. 414-734-9821

SC-142 595-A PRINTED IN U.S.A.

�j I�

�r

LIMITED WARRANTY

EFFECTIVE: AUGUST 6, 1990

L�

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

LIMITED WARRANTY � Subject to the terms and conditions

hereot. MILLER Electric Mfg. Co., Appleton, Wisconsin war

rants to its Distributor/Dealer that all new and unused

Equipment furnished by MILLER is tree trom defect in

workmanship and material as of the time and place of deliveryby MILLER. No warranty is made by MILLER with respect to

engines, trade accessories or other items manufactured byothers. Such engines, trade accessories and other items are

sold sublect to the warranties of their respective manufacturers,

if any. All engines are warrantied by their manufacturer for two

years from date of original purchase, except Deutz engineswhich have a one year. 2000 hour warranty.

Except as specified below, MILLER�s warranty does not applyto components having normal useful life of less than one (1)year, such as spot welder tips, relay and contactor points,MILLERMATIC parts that come in contact with the welding wire

including nozzles and nozzle insulators where failure does not

result from defect in workmanship or material.

MILLER shall be required to honor warranty claims on war

ranted Equipment in the event of failure resulting from a defect

within the following periods from the date of delivery of

Equipment to the original user:

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

components2. Load banks 1 year

3. Original main power rectifiers 3 years

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

. . .

90 days5. All other MILLERMATIC Feeders 1 year

6. Replacement or repair parts, exclusive of labor 60 days7. Batteries 6 months

provided that MILLER is notified in writing within thirty (30) daysof the date of such failure.

As a matter of general policy only, MILLER may honor claims

submitted by the original user within the foregoing periods.

In the case of MILLER�s breach of warranty or any other dutywith respect to the quality of any goods, the exclusive remedies

therefore shall be. at MILLER�s option (1) repair or (2) replacement or, where authorized in writing by MILLER in appropriatecases, (3) the reasonable cost of repair or replacement at an

authorized MILLER service station or (4) payment of or credit

for the purchase price (less reasonable depreciation based

upon actual use) upon return of the goods at Customers risk

and expense. MILLER�s option of repair or replacement will be

F.O.B., Factory at Appleton. Wisconsin. or FOB. at a MILLER

authorized service facility, therefore, no compensation for

transportation costs of any kind will be allowed. Upon receipt of

notice of apparent defect or failure, MILLER shall instruct the

claimant on the warranty claim procedures to be followed.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE-.

SENTATION AS TO PERFORMANCE, AND ANY REMEDY

FOR BREACH OF CONTRACT WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION. OPERATIQNOF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,INCLUDING ANY IMPLIED WARRANTY OF MERCHAN

TABiLITY OR OF FtTNESS FOR PARTICULAR PURPOSE.

WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN

WRITING, MILLER PRODUCTS ARE INTENDED FOR

ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL

USERS AND FOR OPERATION BY PERSONS TRAINED

AND EXPERIENCED IN THE USE AND MAINTENANCE OF

WELDING EQUIPMENT AND NOT FOR CONSUMERS OR

CONSUMER USE. MILLER�S WARRANTIES DO NOT

EXTEND TO, AND NO RESELLER IS AUTHORIZED TO

EXTEND MILLER�S WARRANTIES TO, ANY CONSUMER.

UUI

OM-1584A - 9/91

RECEIVING-HANDLING

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

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

from the distributor and/or the equipment manufactur- Model_________________________________________

er�s Transportation Department.Serial or Style No.

_____________________________

When requesting information about this equipment, al

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

Number.

TABLE OF CONTENTS

Section No. Page No.

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

1-1. Introduction 1

1-2. General Precautions 1

1-3. Arc Welding 4

1-4. Standards Booklet Index 5

SECTION 2 � SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. General Information And Safety 6

2-2. Safety Alert Symbol And Signal Words 6

SECTION 3� SPECIFICATIONS

3-1. DESCRIPTION 7

SECTION 4- INSTALLATION OR RELOCATION

4-1. Location 8

4-2. Base And Boom Assembly 8

4-3. Installation Of Control Box To Base 10

4-4. Installation Of Wire Support 10

4-5. Installation Of Wire Guide Extension 10

4-6. Wire Guide And Drive Roll Installation 10

4-7. Welding Gun Connections 11

4-8. Connections From Boom To Control Box 12

4-9. Shielding Gas Connection 13

4-10. Welding Power Source Connections To Control Box And Boom 13

4-11. Motor Start Control 14

4-12. DIP Switches 15

4-13. Voltage Sensing Connection (Optional) 18

4-14. Run-In Control Connections (Optional) 18

4-15. Synergic Connections (Optional) 18

4-16. Welding Wire Installation 18

4-17. Safety Collar Removal 18

4-18. Boom Adjustments 19

4-19. Welding Wire Threading 19

4-20. Changing From Standard Digital Voltage Control To MILLER Inverter

Digital Voltage Control 20

Section No. Page No.

SECTION 5�OPERATOR CONTROLS

5-1. Power Switch 21

5-2. Wire Speed Controls 21

5-3. Jog/Purge Switches 21

5-4. Voltage Control(s) (Optional) 22

5-5. Digital Voltage Control(s) (Optional) 22

5-6. Burnback Control(s) (Optional) 22

5-7. Preflow Control(s) (Optional) 22

5-8. Postflow Control(s) (Optional) 22

5-9. Trigger Hold Switch(es) (Optional) 22

5-10. Spot/Continuous Switch(es) And Spot Time Control(s) (Optional) 23

5-11. Digital Meter (Optional) 23

5-12. Run-In Control(s) (Optional) 23

5-13. Dual Schedule Control(s) (Optional) 23

5-14. Digital Dual Schedule Control(s) (Optional) 24

SECTION 6� SEQUENCE OF OPERATION

6-1. Gas Metal Arc Welding (GMAW) And Flux Cored Arc Welding(FCAW) 24

6-2. Shutting Down 25

SECTION 7� MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance 25

7-2. Reinstallation Of Hub Assembly 26

7-3. Brush Inspection And Replacement 27

7-4. Overload Protection 27

7-5. Circuit Board Handling Precautions 28

7-6. Troubleshooting 28

SECTION 8� ELECTRICAL DIAGRAMS

Diagram 8-1. Circuit Diagram For Wire Feeder 31

Diagram 8-2. Circuit Diagram For Wire Feeder With Optional Equipment 32

Diagram 8-3. Wiring Diagram For Wire Feeder 34

SECTION 9� PARTS LIST

Figure 9-1. Main Assembly 36

Figure 9-2. Support, Hub & Reel 39

Figure 9-3. Control Box 40

Figure 9-4. Boom Assembly 44

Figure 9-5. Wire Drive Assembly 46

Figure 9-6. Panel, Front w/Components 48

Figure 9-7. Control Panel 50

Optional Equipment 52

LIST OF CHARTS AND TABLES

Table 3-1. Specifications 7

Table 3-2. Options Compatibility 8

Table 7-1. Maintenance Schedule 25

Table 7-2. Troubleshooting 29

Table 9-1. Drive Roll And Wire Guide Kits 43

SECTION 1 � SAFETY RULES FOR PLASMA ARC CUTTING (PAC)

1-1. INTRODUCTION

We learn by experience. Learning safety through per

sonal experience, like a child touching a hot stove, is

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

ers teach you.

Safe practices developed from experience in the use of

welding and cutting are described in this manual. From

research, development, and field experience have

evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when

equipment is improperly used or maintained. The rea

son for the safe practices may not always be given.Some are based on common sense; others may requiretechnical volumes to explain. It is wiser to follow the

rules.

Read and understand these safe practices before at

tempting to install, operate, or service the equipment.Comply with these procedures as applicable to the par

ticular equipment used and their instruction manuals for

personal safety and for the safety of others.

Failure to observe these safe practices may cause seri

ous injury or death. When safety becomes a habit, the

equipment can be used with confidence.

These safe practices are divided into two Sections:

1-General Precautions, common to arc welding and cut

ting; and 2-Plasma Arc Cutting (PAC).

Reference standards. Published Standards on safetyare also available for additional and more complete procedures than those given in this manual. They are listed

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

most complete.

The National Electrical Code, Occupational Safety and

Health Administration, local industrial codes, and local

inspection requirements also provide a basis for equipment installation, use, and service.

1-2. GENERAL PRECAUTIONS

Different metals and metal coatings can producedifferent fumes, gases, and radiation levels. In addi

tion to the information in this manual, be sure to

consult the manufacturers� Material Safety Data

Sheets (MSDS5) for specific technical data and pre

cautionary measures concerning any materials or

coatings on materials cut with this equipment.

A. Burn Prevention

Wear protective clothing�gauntlet gloves designed for

use in welding or cutting, hat, and high safety-toe shoes.Button shirt collar and pocket flaps, and wear cuffless

trousers to avoid entry of sparks and slag.

Wear helmet with safety goggles or glasses with side

shields underneath and appropriate filter lenses or

plates (protected by clear cover glass). This is a MUST

for welding or cutting (and chipping or grinding) to protect the eyes from radiant energy or flying metal. Re

place cover glass when broken, pitted, or spattered. See1 -3A.2.

Avoid oily or greasy clothing. A spark may ignite them.

Hot metal, such as the workpiece, should never be han

dled without gloves.

Medical first aid and eye treatment. First aid facilities and

a qualified first aid person should be available for each

shift unless medical facilities are close by for immediate

treatment of flash burns of the eyes and skin burns.

Ear plugs should be worn when working overhead or in a

confined space. A hard hat should be worn when others

work overhead.

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

B. Toxic Fume Prevention

Severe discomfort, illness, or death can result from

fumes, vapors, heat, or oxygen enrichment or depletionthat welding or cutting may produce. Prevent this with

adequate ventilation as described in ANSI Standard

Z49.1 listed in Standards Index. NEVER ventilate with

oxygen.

Lead-, cadmium -,zinc-, mercury-, and beryllium-bearing and similar materials, when welded or cut, may pro

duce harmful concentrations of toxic fumes. Adequatelocal exhaust ventilation must be used, or each person in

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

used.

Metals coated with or containing materials that emit toxic

fumes should not be heated or cut unless coating is re

moved from the work surface, the area is well ventilated

or, if necessary, while wearing an air-supplied respirator.

Work in a confined space only while it is being ventilated

and, if necessary, while wearing an air-supplied 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.

When leaving a confined space, shut OFF gas supply at

source to prevent possible accumulation of gases in the

space if downstream valves have been accidentallyopened or left open. Check to be sure that the space is

safe before reentering it.

Vapors from chlorinated solvents can be decomposed

by the heat of the arc to form PHOSGENE, a highly toxic

gas, and other lung and eye irritating products. The ultra-

OM.1584 Page 1

violet (radiant) energy of the arc can also decompose

trichloroethylene and perchioroethylene vapors to form

phosgene. DO NOT WELD OR CUT where solvent va

pars can be drawn into the welding or cutting atmos

phere, or where the radiant energy can penetrate to at

mospheres containing even minute amounts of

trichioroethylene or perchioroethylene.

C. Fire and Explosion Prevention

Causes of fire and explosion are as follows: combus

tibles 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 travel great dis

tances.

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 the area, do NOT weld or cut.

Move the work, if practicable, to an area free of comb

ustibles. Avoid paint spray rooms, dip tanks, storage ar

eas, and ventilators. If the work cannot be moved, move

combustibles at least 35 feet away out of reach of sparksand heat; or protect against ignition with suitable and

snug-fitting, fire-resistant covers or shields.

Walls touching combustibles on opposite sides should

not be welded on or cut. Walls, ceilings, and floor near

work should be protected by heat-resistant covers or

shields.

Fire watcher must be standing by with suitable fire extin

guishing equipment during and for some time after weld

ing or cutting if:

a. appreciable combustibles (including buildingconstruction) are within 35 feet

b. appreciable combustibles are further than 35

feet but can be ignited by sparks

c. openings (concealed or visible) in floors or walls

within 35 feet may expose combustibles to

sparks

d. combustibles adjacent to walls, ceilings, roofs,

or metal partitions can be ignited by radiant or

conducted heat.

Hot work permit should be obtained before operation to

ensure supervisor�s approval that adequate precautionshave been taken.

After work is done, check that area is free of sparks,glowing embers, and flames.

An empty container that held combustibles, or that can

produce flammable or toxic vapors when heated, must

never be welded on or cut, unless container has first

been cleaned as described in AWS Standard F4.l,listed

7 in Standards Index. This includes a thorough steam or

caustic cleaning (or a solvent or water washing, depending on the combustible�s solubility) followed by purgingwith nitrogen or carbon dioxide, and using protective

equipment as recommended in F4.l.

A container with unknown contents should be cleaned

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

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

Hollow castings or containers must be vented before

welding or cutting. They can explode.

Explosive atmospheres. Never weld or cut where the air

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

0. Compressed Gas Equipment

Standard precautions. Comply with precautions in this

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

DERS, listed 11 in Standards Index.

1. Pressure Regulators

Regulator relief valve is designed to protect only the

regulator from overpressure; it is not intended to protect

any downstream equipment. Provide such protectionwith one or more relief devices.

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

Remove faulty regulator from service immediately for re

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

External gas leaks.

Excessive Creep.If delivery pressure continues to rise with downstream

valve closed.

Faulty Gauge.If gauge pointer does not move off stop pin when pres

surized, nor returns to stop pin after pressure release.

Repair.Do NOT attempt to repair. Send faulty regulators for re

pair to manufacturer�s designated repair center, where

special techniques and tools are used by trained person-

nel.

2. Cylinders

Cylinders must be handled carefully to prevent leaks and

damage to their walls, valves, or safety devices.

Avoid electrical circuit contact with cylinders includingthird rails, electrical wires, and welding or cutting cir

cuits. They can produce short circuit arcs that may lead

to a serious accident. (See 1 -3C.)

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

assurance of safety when the cylinder is properly handled.

Identifying gas content. Use only cylinders with name of

gas marked on them; do not rely on color to identify gascontent. Notify supplier if unmarked. NEVER DEFACE

or alter name, number, or other markings on a cylinder. It

is illegal and hazardous.

OM-1584 Page 2

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. Never cut on a cylinder.

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 arcs, excessive heat,

sparks, slag, 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 securelywhen moving cylinders.

Stuck valve. Do NOT use a hammer or wrench to open a

cylinder valve that cannot be opened by hand. Notifyyour supplier.

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

Never refill any cylinder.

Cylinder fittings should never be modified or exchanged.

3. Hose

Prohibited use. Never use hose other than that designedfor the specified gas. A general hose identification rule is

as follows: red for fuel gas, green for oxygen, and black

for inert gases.

Use ferrules or clamps designed for the hose (not ordi

nary wire or other substitute) as a binding to connect

hoses to fittings.

No copper tubing splices. Use only standard brass fit

tings to splice hose.

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

Coil excess hose to prevent kinks and tangles.

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

Examine hose regularly for leaks, wear, and loose con

nections. Immerse pressurized hose in water; bubbles

indicate leaks.

Repair leaky or worn hose by cutting area out and splic

ing (1-2D3). Do NOT tape.

4. Proper Connections

Clean cylinder valve outlet of impurities that may clogorifices and damage seats before connecting regulator.Except for hydrogen, crack valve momentarily, pointingoutlet away from people and sources of ignition. Wipewith a clean lintless cloth.

Match regulator to cylinder. Before connecting, check

that the regulator label and cylinder marking area, and

thatthe 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 identified

by right-hand threads for oxygen and left-hand threads

(with grooved hex on nut or shank) for fuel gas.

5. Pressurizing Steps

Drain regulator of residual gas through suitable vent be

fore opening cylinder (or manifold valve) by turning ad-

lusting screw in (clockwise). Draining prevents exces

sive compression heat at high pressure seat by allowingseat to open on pressurization. Leave adjusting screw

engaged slightly on single-stage regulators.

Stand to side of regulator while opening cylinder valve.

Open cylinder valve slowly so that regulator pressure in

creases slowly. When gauge is pressurized (gaugereaches regulator maximum), leave cylinder valve in fol

lowing position: For oxygen and inert gases, open fullyto seal stem against possible leak. For fuel gas, open to

less than one turn to permit quick emergency shutoff.

Use pressure charts (available from your supplier) for

safe and efficient recommended pressure settings on

regulators.

Check for leaks on first pressurization and regularlythereafter. Brush with soap solution (capfull of Ivory Liquid* or equivalent per gallon of water). Bubbles indicate

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

bustible.

E. User ResponsibilitIes

Remove leaky or defective equipment from service im

mediately for repair. See User Responsibility statement

in equipment manual.

F. Leaving Equipment Unattended

Close gas supply at source and drain gas.

G. Rope Staging-Support

Rope staging-support should not be used for welding or

cutting operation; rope may burn.

*Tradernark of Proctor & Gamble.

OM-1584 Page 3

1-3. PLASMA ARC CUTTiNG (PAC)

Comply with precautions in 1-1, 1-2, and this section.

Plasma Arc Cutting, properly done, is a safe process, but

a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very

bright and hot. Sparks fly, fumes rise, ultraviolet and in

frared energy radiates, workpieces are hot, and com

pressed gases may be used. The wise operator avoids

unnecessary risks and protects himself and others from

accidents. Precautions are described here and in stan

dards referenced in index.

A. Burn Protection

Comply with precautions in 1-2.

The electric arc used in cutting is intense and visiblybright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and

burn the skin and eyes. Skin burns resemble acute sun

burn; those from gas-shielded arcs are more severe and

painful. DON�T GET BURNED; COMPLY WITH PRE

CAUTIONS.

1. Protective Clothing

Wear long-sleeve clothing in addition to gloves, hat, and

shoes (1-2A). As necessary, use additional protectiveclothing such as leather jacket or sleeves, flame-proofapron, and fire-resistant leggings. Avoid outer garmentsof 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.

A proper welding helmet or shield containing a filter plateshade according to ANSI Z49. 1 and ANSI Z87. 1 must be

used when cutting. Place over face before beginning to

Cut.

Protect filter plate with a clear cover plate.

Cracked or broken helmet or shield should NOT be

worn; radiation can pass through to cause burns.

Cracked, broken, or loose filter plates must be replacedIMMEDIATELY. Replace clear cover plate when broken,

pitted, or spattered.

Flash goggles with side shields MUST be worn under the

helmet to give some protection to the eyes should the

helmet not be lowered over the face before cutting is

started. Looking at an arc momentarily with unprotectedeyes (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 cutting area. For production cutting, a separate room or enclosed bay is best. In open areas, sur

round the operation with low-reflective, non-combusti

ble screens or panels. Allow for free air circulation, particularly at floor level.

Viewing the cut. Provide proper face shields for all per

Sons who will be looking directly at the cut.

Others working in area. See that all persons are wearingproper flash goggles.

Before starting to Cut, make sure that screen flaps or baydoors 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 cuttingequipment. It may overheat cables and cause a fire.

Loose cable connections may overheat or flash and

cause a fire.

Never cut on a cylinder or other pressure vessel. It can

cause a violent rupture or lead to such a rupture under

rough handling.

D. Compressed Gas Equipment

Comply with precautions in 1-2D.

E. Shock Prevention

Exposed hot conductors or other bare metal in the cut

ting 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 cutting without suitable pro-tection.

To protect against shock:

Wear dry insulating gloves and body protection. Keepbody and clothing dry. Never work in a damp area with

out adequate insulation against electrical shock. Stay ona dry duckboard or rubber mat when dampness or sweat

cannot be avoided. Sweat, sea water, or moisture be

tween the body and an electrically HOT part or groundedmetal reduces the electrical resistance, and could en

able dangerous and possibly lethal currents to flow

through the body.

A voltage will exist between the cutting torch electrode

and any conducting object in the work circuit. Examplesof conducting objects include, but are not limited to,

buildings, electrical tools, work benches, power source

cases, workpieces, etc. Never touch the cutting torch

electrode and any metal object unless the powersource is OFF.

1. Grounding the Equipment

Plasma arc cutting equipment must be grounded ac

cording to the National Electrical Code, and the work

must be grounded according to ANSI Z49.1, �Safety In

Welding And Cutting.� Locate grounding terminal or

grounding lead (green or green with yellow stripe). This

is the first connection that should be made.

OM-1584 Page 4

When installing, connect the frames of each unit, such

as power source, control, worktable, and water circula

tor to the building ground. Conductors must be adequateto carry ground currents safely. Equipment made electri

cally HOT by stray current-may shock, possibly fatally.Do NOT GROUND to electrical conduit, or to a pipe car

rying ANY gas or flammable liquid such as oil or fuel.

Three-phase connection. Check phase requirements of

equipment before installing. If only 3-phase power is

available, connect single-phase equipment to only two

wires of the 3-phase line. Do NOT connect the equipment ground to the third (live) wire, or the equipment will

become electrically HOT�a dangerous condition that

can shock, possibly fatally.

Before cutting, check ground for continuity. Be sure con

ductors 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-prongplug is added for connection to a grounded mating re

ceptacle, the ground lead must be connected to the

ground prong only. If the line cord comes with a three-

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

plug with a broken off ground prong.

2. Plasma Cutting Torches

Fully insulated torches should be used. Do NOT use

torches with protruding screws.Do NOT use torches with

cracks on pieces missing or with loose or missingscrews.

3. Cables

Frequently inspect cables for wear, cracks, and dam

age. IMMEDIATELY REPLACE those with excessivelyworn 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 protectedfrom hot metal and sparks.

4. Terminals And Other Exposed Parts

Terminals and other exposed parts of electrical units

should have insulating covers secured before operation.

5. Cutting Torch Disassembly

Even though there are several safety shutdown devices

provided as standard equipment on the cutting torch, it is

still a recommended safe practice to turn off the power

source before touching any torch parts.

Power sources used for the Plasma Arc Cutting (PAC)

process normally are equipped with devices that permiton-off control of the cutting power output. As a result, the

cutting torch electrode and tip become electrically HOT

whenever the power source is ON and the cutting torch

switch is closed (pressed).

Never touch the torch tip or electrode and any conduct

ing object in contact with the cutting circuit unless the

power source is OFF.

6. Safety Devices

Safety devices, such as interlocks and circuit breakers,should not be disconnected or shunted out.

Before installation, inspection, or service of equipment,shut OFF all power, and remove line fuses (or lock or

red-tag switches) to prevent accidental turning ON of

power. Disconnect all cables from power source, and re

move all 115 volts line-cord plugs from receptacles.

Do not open power circuit while cutting. If, in an emer

gency, it must be disconnected, guard against shock,

burns, or flash from switch arcing.

Never leave equipment unattended. Always shut OFF

and disconnect all power to equipment before leaving.

Power disconnect switch must be available near the

plasma cutting power source.

1-4. STANDARDS BOOKLET INDEX

For more information, refer to the following standards or

their latest revisions, and comply as applicable:

1. ANSI Standard Z49.1, SAFETY IN WELDING

AND CUTTING, obtainable from the American

Welding Society, 550 N.W. LeJeune Rd. Miami,FL 33126.

2. NIOSH, SAFETY AND HEALTH IN ARC WELD

ING AND GAS WELDING AND CUTTING, ob

tainable from the Superintendent of Documents,

U.S. Government Printing Office, Washington,D.C. 20402.

3. OSHA, SAFETY AND HEALTH STANDARDS,29 CFR 1910, obtainable from the Superintendent of Documents, U.S. Government PrintingOffice, Washington, D.C. 20402.

4. ANSI Standard Z87.1, PRACTICE FOR OCCU

PATIONAL AND EDUCATIONAL EYE AND

FACE PROTECTION, obtainable from the Ameri

can National Standards Institute, 1430 Broad

way, 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 PROC

ESSES, obtainable from the American National

Standards Institute, 1430 Broadway, New York,

NY 10018.

OM-1584 Page 5

7. American Welding Society Standard AWS F4.1,

RECOMMENDED SAFE PRACTICES FOR THE

PREPARATION FOR WELDING AND CUTTING

OF CONTAINERS THAT HAVE HELD HAZARD

OUS SUBSTANCES, obtainable from the Ameri

can Welding Society, 550 N.W. LeJeune Rd, Mi

ami, FL 33126.

8. NFPA Standard 51, OXYGEN-FUEL GAS SYS

TEMS FOR WELDING, CUTTING, AND ALLIED

PROCESSES, obtainable from the National Fire

Protection Association, Batterymarch Park,

Quincy, MA 02269.

9. NFPA Standard 70, NATIONAL ELECTRICAL

CODE, obtainable from the National Fire Protec

tion Association, Batterymarch Park, Quincy, MA

02269.

10. NFPA Standard 518, CUTTING AND WELDING

PROCESSES, obtainable from the National Fire

Protection Association, Batterymarch Park,

Quincy, MA 02269.

11. CGA Pamphlet P-i,SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable

from the Compressed Gas Association, 1235 Jef

ferson Davis Highway, Suite 501, Arlington, VA

22202.

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

WELDING AND CUTTING, obtainable from the

Canadian Standards Association, Standards

Sales, 178 Rexdale Boulevard, Rexdale, Ontario,Canada M9W 1 R3.

13. NWSA booklet, WELDING SAFETY BIBLIOG

RAPHY, obtainable from the National WeldingSupply Association, 1900 Arch Street, Philadel

phia, PA 19103.

14. American Welding Society Standard AWS C5.2,

RECOMMENDED PRACTICES FOR PLASMA

ARC CUTTING, obtainable from the American

Welding Society, 550 N.W. LeJeune Rd, Miami,FL 33126.

15. ANSI Standard Z88.2, PRACTICE FOR RESPI

RATORY PROTECTION, obtainable from the

American National Standards Institute, 1430

Broadway, New York, NY 10018.

OM-1584 Page 6

SECTION 3� SPECIFICATIONS

Table 3-1. Specifications

Model Dual 12 Dual 16

Electrode Wire Diameter Capacity 0.023 thru 118 in. (0.6 thru 3.2 mm)

Speed Range 50 � 780 ipm (1.3 � 19.8 mpm)

Control Circuit Voltage At Gun 24 Volts AC

Boom Length 12 ft. (3.7 m) 16 ft. (4.9 m)

Swing 360°

Vertical Lift Horizontal To 60° Above

21 ft. (6.4 m)17ft. (5.2m)

Compression Spring Is Designed To Balance Boom

At Any Angle. Pressure Adjustment Is Provided To

Hold The Boom At Any Desired Angle Or To Limit The

Vertical Lift At 40°, 50°, or 60°.

Maximum Heiaht (With 4 ft. or

1.2 m Post) At pull Lift Of Boom

Counterbalance

(Patented)

Weight

Net I Ship Net Ship

280 lbs. I 411 lbs.

(127 kg) (186 kg)207 lbs.

I318 lbs.

(94 kg) (144 kg)

*Optional high speed motor range: 90 to 1400 ipm (2.3 to 35.6 mpm)

3-1. DESCRIPTION

This unit is a boom mounted semiautomatic constant

speed wire feeder which operates on 24 volts ac. This

unit has the capability of feeding wire alternately from

two welding guns. The feeder is designed for connection

to a constant voltage type welding power source througha 1 4-pin connector. If 115 volts ac is the only power avail

able for use with the feeder, the optional power supply

adapter Model PSA-2 115/24 is required to convert the

power to 24 volts ac.

The case is tightly secured to help keep out dust and dirt,while still allowing easy access to optional controls.

The boom is a patented design allowing both vertical and

horizontal lift and swing. Cables are routed through the

boom from the control to the wire drive assembly.

The following optional equipment can be provided on the

wire feeder and is covered within this Owner�s Manual:

* Digital Meter/Tachometer Feedback

* Voltage Control

* Digital Voltage Control

* Burnback Control

* Four In One - Which includes the following:

Spot/Burnback Control

Preflow Control

Postflow Control

Trigger Hold

* Option Interface (required to install the followingoptions)

* Run-In Control

* Dual Schedule

* Digital Dual Schedule

* Synergic Connections

IMPORTANT: For a complete listing of Options andAc

cessories, see back cover of this wire feeder Owner�s

Manual.

OM-1584 Page 7

Table 3-2. Options Compatibility - -

The table below should be used to determIne the options that can be used together on a wire feeder. Use the column on the left side of the

table to choose the desired option and follow the line across to see which options are compatible.

DESIRED OPTION�-

Burn-

back

Control

4-~-1

OptIon

DIgItalMeter/

Tech

Feedback

Olaltal

~Control

VoltageControl

Run-In

Control

DIgItalDual

Scheduli

Dual

Schedule

Control

Remote

Pendant

Control

Cord

#137 552

(For

RCSP-45)

Burnback Control � No Yes Yes Yes Yes Yes Yes Yes Yes

4-IN-i Option (Includes preflowlpostflow,spotlburnback, and trigger hold Control)

No � Yes Yes Yes Yes Yes Yes Yes Yes

Digital Meter/Tach Feedback Yes Yes � Yes Yes Yes Yes No Yes Yes

Digital Voltage Control (DVC) Yes Yes Req�d � No Yes Yes No Yes No

Voltage Control Yes Yes Yes No � Yes No No No No

Run-In Control

(Option Interface Required)

Yes Yes Yes Yes Yes � Yes Yes Yes Yes

Digital Dual Schedule


Yes Yes Req�d Reqd No Yes � No No No

Dual Schedule Control


Yes Yes No No No Yes No � No No

Remote Pendant Control


Yes Yes Yes Yes No Yes No No � No

Cord #137 552 (For RCSP-45)(Option Interface Required)

Yes Yes Yes No No Yes No No No �

SECTION 4� INSTALLATION OR RELOCATION

4-1. LOCATION

The service life and efficiency of this unit and associated

components are reduced when they are subjected to

high levels of dust, dirt, moisture, corrosive vapors, and

extreme heat.

A suitable location for this unit will allow room for the

boom to swing horizontally in the desired arc and to pivotupward to the desired angle. Proper placement will also

provide sufficient clearance from obstruction at the wire

support end of the unit when the boom swings. The

structure to which the unit is being installed should be of

sufficient construction to support the weight of the unit

when the boom is in the horizontal position.

4-2. BASE AND BOOM ASSEMBLY (Figure 4-1)

1. Existing Support (Customer Supplied)

a WARNING: FALLING BOOM can cause serI

ous personal injury and equipment damage.� Use 5 in. (127 mm) diameter, Schedule 40

pipe (wall thickness of 0.258 in. or 6.6mm) as

support pipe for 16 foot (4.9 m) booms.

a. Uncrate and remove all packing material from

the unit.

b. Mount post support to the desired structure.

OM-i 584 Page 8

Wire Guide Fitting

a WARNING: FALLING BOOM can cause seri

ous personal injury and equipment damage.� Securely mount unit to a structure that can

support the weight of the unit when the boom

is in the horizontal position.

c. Complete Steps c thru g in Subsection 2. Post

Support.

2. Post Support (Optional)

a. Uncrate and remove all packing material from

the unit.

b. Mount post support to desired structure.

a WARNING: FALLING BOOM can cause serious personal injury and equipment damage.� Securely mount unit to a structure that can

support the weight of the unit when the boom

is in the horizontal position.

c. Remove yoke pin, nut, washers, and bolt from

yoke and swivel plates.

Hole in Yoke

Yoke

Cotter Pin

Screw

Lock Washer

a WARNING: RELEASE OF SPRING PRESSURE WITHOUT BOOM ATTACHED can

cause serious personal Injury and equipment damage.� Perform installation exactly as outlined in fo!

lowing step-by-step instructions.

� Do not remove safety collar until instructed to

do so.

d. Insert swivel into post.

e. Place the boom base plate between the two

swivel plates.

f. Slide washer onto bolt and insert through appropriate hole in swivel plates (see inset portion of

Figure 4-1). Slide washer onto bolt and install

nut onto bolt. Tighten nut; then back off nut 1/2

turn.

g. Insert pin through yoke, hole, and install cotter

pin through pin.

CAUTION: EXCESSIVE FRICTION can dam

age equipment.� Every six months lubricate swivel to preventwear

Excessive lubrication is not required or recom

mended.

Wire Support

Swivel Base

Nut

Washer

Post Support

Figure 4-1. Base And Boom Assembly

SB-142 598.A

OM-1 584 Page 9

3. Base Support (Optional) remaining end of monocoil liner is flush with end

IMPORTANT: If an optional base support was pur-of tube.

chased with the unit, mounting holes are provided for 3. Tighten bolt to secure monocoil liner. Be sure not

fastening the base support to the floor, to crush the liner.

~ WARNING: FALLING BOOM can cause seri

ous personal injury and equipment damage. 4-6. WIRE GUIDE AND DRIVE ROLL INSTALLA

� For mounting base support use, as a mini- lION (Figure 4-2)

mum, 1/2 in. (12.7 mm) diameter, S.A.E.Upon initial installation, or as a result of changes in wire

grade 5 bolts.size and type, it is necessary to install the required drive

� Use equivalent strength, non-corrosive bolts rolls and wire guides. Select drive rolls according toif unit is mounted in an extremely damp envi- Table 9-1.ronment.

IMPORTANT: All directions for wire guide and drive rolla. Uncrate and remove all packing material from

installation such as left and right, are with respect to thethe unit.

operator facing the front of the drive assembly.b. Fasten base support to the floor.

c. Complete Steps c thru g in Subsection 2. Post IMPORTANT: All adjustments are made usinga3/l6in.

Support. Follow all precautionary data. alien wrench, which is included with this unit.

4. Swingpak Base (Optional)After obtaining the appropriate drive rolls and wire

a. Uncrate and remove all packing material from guides, proceed as follows:the Swingpak base.

A. Wire Guide Installation

A~ WARNING: FALLING BOOM can cause seri

ous personal injury and equipment damage. 3. Open drive assembly cover.

� Mount welding power source on Swingpak4. Remove drive rolls if applicable.base before mounting Swingarc.5. Loosen the wire guide screw and wire guide re

b. Uncrate and remove all packing material fromtamer.

the Swingpak unit.

6. Place wire guide with arrow pointing down, intoc. Complete Steps c thru g in Subsection 2. Post

Support. Follow all precautionary data. guide holder seat.

7. Secure wire guide by tightening wire guide screw,4-3. INSTALLATION OF CONTROL BOX TO BASE

making certain that wire guide retainer is posi(Figures 4-1 And 43) tioned in groove on guide holder seat. Do not

The control box is shipped with four (4) screws partially overtighten.installed into bottom side of control box. To secure con

trol box to base proceed as follows:8. Install remaining wire guide by repeating Steps 2

through 5.1. Set control box onto base with the four screws

protruding through the four keyhole shaped holes B. Drive Roll Installation

in base plate.1. Close spring shaft carrier.

2. Slide control box forward, so that screws are in

slotted portion of keyholes, and tighten the four2. Turn drive roll nut on each drive roll carrier coun

terclockwise until the three lobes of each nut linescrews.

up with the three lobes of each drive roll carrier.

4-4. INSTALLATION OF WIRE SUPPORT3. Open spring shaft carrier.

(FIgure 4-1)

1. Remove the securing screws and lock washers 4. Slide a drive roll over drive roll nut onto drive roll

from the swivel base. carrier.

2. Place the wire support over the holes in the swivel 5. Repeat Step 4 for all drive rolls.

base.6. Close spring shaft carrier, and turn each drive roll

3. Insert securing screws with lock washers and nut clockwise until tight. Do not overtighten.tighten.

C. Drive Roll Pressure Adjustment4-5. INSTALLATION OF WIRE GUIDE EXTENSION

(Figure 43)The drive roIl pressure indicator is located on the topfront side of the spring shaft carrier. The scale on the in-

1. Locate supplied wire guide extension. dicator is a relative scale only, and does not indicate ac

2. Loosen bolt on wire guide fitting, and insert end of tual drive roll pressure. Increase drive roll pressure bymonocoil liner near cable tie into fitting. Be sure rotating the pressure adjustment knob clockwise.

OM-1584 Page 10

FIgure 4-2. Wire Guide And Drive Roll Installation

4-7. WELDING GUN CONNECTIONS

A. Gun Connector To Drive Assembly (ProvidesWeld Power And Shielding Gas) (Figure 4-2)

IMPORTANT: The outlet guide is provided as part of the

gun or gun adapter assembly.

1. Loosen the gun/feeder connector securing knob.

IMPORTANT: The outlet guide should be installed so

that tip of guide is as close to the drive rolls as possiblewithout touching.

2. Insert the gun/feeder connector, or gun/feederadapter if required, which includes installed outlet

guide, into drive assembly opposite inlet guide.

3. Tighten gun/feeder connector securing knob.

B. Gun Trigger (Figure 4-3)

a WARNING: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.

� Do not touch electrode wire when gun triggeris pressed.

The welding wire and all metal parts in contact

with it carry weld output when the welding powersource contactor is energized.

Two 4 socket free-hanging receptacles extend Out of the

motor end of the boom for connecting the gun triggerplugs to the wire feeder. Connect the left gun to the free-

hanging receptacle labeled LEFT, and the right gun to

the remaining free-hanging receptacle. To make con

nections, align keyways, insert plug, and rotate threaded

collar fully clockwise.

Set Screw

Liner

Wire Guide

Weld CableTerminal

Drive Roil

Carrier

Drive RollPressure indicator

pring Shaft Carrier

(Shown Open)

Drive Roll

Nut

~One PieceDrive Roll

Pressure

AdjustmentKnobGun/Feeder

Connector

OpeningGun/FeederConnector

Securing Knobs

Guide HolderSeat.

Wire

Guide

Wire GuideRetainer

WireScrew

Guide HolderSeat Groove

SA-142 597

SA�137 391-A

OM-1584 Page 11

C. Shielding Gas (If Applicable) ARCING can damage weld cable terminal.

An integral gas input fitting is provided on the wire drive

assembly for guns utilizing this type of connection. If the

gun requires a separate shielding gas connection, dis

connect the hose from the gas fitting on drive assembly,install proper fittings or connectors, and connect to gas

hose from gun. --

0. Weld Cable (If Applicable)

WARNING: ELECTRIC SHOCK can kill.

_____ � Do not touch live electrical parts.

� Shut down wire feeder and welding powersource anddisconnect inputpoweremployinglockout/tagging procedures before makingweld cable connections.

Lockout/tagging procedures for the wire feeder

consist of disconnecting interconnecting cord,and for welding power source consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect

ing device. Stop engine, and disconnect negative (�) battery cable from battery on weldinggenerators.

� Clean weld cable terminal before connectingweld cable if necessary.

� Tighten terminal nut securely.

Loose or dirty connections can cause erratic

weld output.

Connect the weld cable from the gun, if applicable, to the

weld cable terminal on the drive assembly.

4-8. CONNECTIONS FROM BOOM TO CONTROL

BOX (Figure 4-3)

A. Gun Trigger

Two receptacles, labeled TRIGGER RECEPTACLE,

are provided on the front of the control box. Connect the

left gun trigger control plug from the boom, labeled

LEFT, to control box left TRIGGER RECEPTACLE. Con

nect remaining gun trigger control plug to matching re

ceptacle. To make connections, align keyways, insert

plug, and rotate threaded collar fully clockwise.

Ref. SD-I 42 598-A

Control Motor ControlBox Plugs

TriggerControl

Plugs

GasHoses

WeldCables

Wire Guide

FitlIng

WeldCable

Liner

Gun TriggerPlugs

Figure 4-3. Control Box And Boom ConnectIons

OM-1584 Page 12

10 ft. (3 m) Gas Hose with Extension

Adapter (supplied with feeder)

10 ft. (3 rn) 24 VAC and ContactorCord (supplied with feeder)

10 ft. (3 m) Weld Power Cable (supplied with feeder)

Standard or

Deluxe Model

10 ft. (3 m) Gas Hose with Extension

Miller electrically Adapter (supplied with feeder)controlled CV and

CCICV power source

with a 14-pin lOft. (3 m) 24 VAC and Contactor I I Standard Deluxe orreceptacle and 24 VAC Cord (supplied with feeder) ~ k Super Deluxe ModelSupply_______________________________________________________________

lOft. (3 m) Weld Power Cable (supplied with feeder)

Optional PSA-2 Control (allows 60 Series Feeders to be used with power sources

having only 115 VAC available � can be mounted at power source or feeder. Refer

to OPTIONAL CONTROLS AND ACCESSORIES section for detailed information.)

lOft. (3 m) Gas Hose with Extension

�Adapter (supplied with feeder) \

1/10 ft. (3 m) Weld Power Cable (supplied with feeder)

IMPORTANT: If using the SS or DS feeder with a power source having only 115 VAC supply, the PSA-2 (Power Source Adapter) is required.

Refer to OPTIONAL CONTROLS AND ACCESSORIES section.

Figure 4-4. Typical Connections To Welding Power Source

S-0534

B. Motor Control

Two motor control receptacles are provided on the rear

of the control box for making motor control connections.

Connect the left motor control plug from boom, labeled

LEFT, to control box left motor control receptacle. Con

nect remaining motor control plug to matching recep

tacle. To make connections, align keyways, insert plug,and rotate threaded collar fully clockwise.

4-9. SHIELDING GAS CONNECTION (Figure 4-3)

The shielding gas hoses extend lOft. (3 m) from the rear

of the boom. If necessary, obtain extension for hoses.

Route and connect end of gas hose to regulator/flowmeter at gas supply.

4-10. WELDING POWER SOURCE CONNECTIONS

TO CONTROL BOX AND BOOM (Figures 4-3

thru 4-5)

A. 14-Pin Plug Connection

The 14-pin plug PLG lOon the end of the interconnectingcord provides a means for connecting the wire feeder to

a welding power source (see Figure 4-6). This connec

tion provides 24 volt ac power, contactor control, and optional voltage control when used with a constant voltage(CV) welding power source with a 14-socket receptacle.To make connections, align keyway, insert plug, and ro

tate threaded collar fully clockwise.

The pins on plug PLG1O are defined in relation to both

the power source and wire feeder. The welding power

source provides six functions to the wire feeder. The pinsare designated as follows:

FIgure 4-5. Front View Of 14-Pin PlugWith PIn Locations

Ret. S-0512

Miller CV power source

equipped with a 14-pinreceptacle and 24 VAC

supply

Optional 115 VAC and Contactor Cord

or Control Cord from existing 50 Series

feeder installation (cord connects to 4-pinconnector on cord from PSA-2 Control)

EXTENSION CORDS

loft. 3m) #122 972

25 ft. 7.6 m) #122 973

SOft. 15m (#12297475ft. 23m (#122975

Can be added to the standardlOft. (3 m) cord to extend feederfarther from power source.

Miller CV or competitiveCV power source with

115 VAC power or

competitive power source

requiring contact closure

for coritactor control

4-Pin PlugStandard or

J LDeluxe Model

OM-1 584 Page 13

Pin A: Up to 10 amperes of 24 volts ac, 60 Hz, with re

spect to socket G (circuit common); protected

by fuse in welding power source.

Pin B: 24 volts ac input power to energize the weld

contactor. The feeder sends back 24 volts ac bymeans of a contact closure from Pin A to Pin B.

Pin C: +10 volts dc with-respect to Pin D.

Pin D: Control circuit common from power source.

Pin E: Input command signal from wiper of remote

control potentiometer, 0 volts equals machine

minimum; +10 volts equals machine maximum.

Pin G: 24 volts ac circuit common; also connected to

welding power source chassis.

Pin H: Reserved for future use.

IMPORTANT: The remaining pins in the plug are not

used by the feeder.

B. Weld Cable

4~ ELECTRIC SHOCK can kill.


� Shut down wire feeder and welding powersource anddisconr7ectinputpoweremployinglockout/tagging procedures before makingweld cable connections.

Lockoutltagging procedures for the wire feeder

consist of disconnecting interconnecting cord,and for welding power source Consist of padlocking line disconnect switch in open position,removing fuses from fuse box, or shutting off and



ARCING can damage weld cable terminal.

� Clean weld cable terminal before connectingweld cable if necessary

� Tighten terminal nut securely.

Loose or dirty connections can cause erratic

weld output.

Two 10 ft. (3 m) weld cables extend Out of the boom for

making weld output connection to the welding power

source.

For Electrode Positive/Reverse Polarity connections

proceed as follows:

1. Route and connect both weld cables extendingout of the control box end of the boom to the Posi

tive (+) weld output terminal on welding power

source (see power source Owner�s Manual). If

necessary, use a weld cable extension of ade

quate size and capacity to reach power source. If

cable extension is used, securely bolt and insu

late connection point.

2. Route and connect another weld cable of ade

quate size and capacity from the Negative (�)weld output terminal (see power source Owner�s

Manual) to workpiece.

IMPORTANT: For Electrode Negative/Straight Polarityconnections, reverse cable connections to weld outputterminals; electrode becomes negative.

4-11. MOTOR START CONTROL (Figure 4-6)

a ELECTRIC SHOCK can kill.


� Shut down wire feeder and welding powersource anddisconnect inputpoweremployinglockout/tagging procedures before openingcontrol box wrapper.

Lockout/tagging procedures for the wire feeder




ELECTROSTATIC DISCHARGE (ESD) can

damage circuit board components.� Put on properly grounded wrist strapBEFORE handling circuit boards.

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

The Motor Start Control potentiometer R70, located on

the motor control board PCi, provides the ability to se

lect wire feed speed acceleration at the be~inning of wire

feed up to the rate set on the Wire Speed control.

The Motor Start Control is factory set to provide requiredarc starting characteristics with a wide range of weldingpower sources.

To adjust the Motor Start Control, proceed as follows:

1. Remove wrapper.

2. Remove screws from nameplate and side panels,and lower hinged front panel.

3. Adjust R70 using a non-conductive screwdriver.

Rotating the potentiometer clockwise increases

the amount of time it takes the motor to ramp up to

speed.

4. Secure hinged front panel lowered in Step 2.

5. Reinstall and secure wrapper removed in Step 1.

OM-1584 Page 14

4-12. DIP SWITCHES (Figure 4-7)

It may be necessary to change DIP switch positions if dif

ferent options are added, or if different functions are de

Rear

Panel

Wire Clamp

sired. Follow the procedure in Subsection A when

changing DIP switches.

A. Procedure For Changing DIP Switches

To change switch positions, proceed as follows:



� Shut down wire feeder and welding power

source, and disconnect interconnecting cord

from the welding power source before reset

ting DIP switches.

1. Remove wrapper.

2. Locate DIP switches and remove protective coat

ing if necessary.

3. Reposition appropriate DIP switch using a non-

conductive pointed tool, such as the edge of a

small screwdriver.

4. Reinstall wrapper.

DIgital Meter Circuit Board

PC6O And Digital Meter

Functions DIP Switch

Ret. SB.131 819.8

Figure 4-6. Motor Start Control On Motor Control

Board PCi

Left Side View

Optional Interface CircuitBoard PC7O And Remote

input/Run-in Voltage SenseDIP Switch

Tachometer Conversion

Circuit Board PC5O

Motor Board PCi And

Motor Start ControlPotentiometer R70

4-in-i Circuit Board

PC3O or Burnback

Circuit Board PC1O

Digital Voltage Control

Circuit Board PC4ORelay Circuit

Board PC3

Hinged Front Panel

Figure 4-7. Circuit Board And DIP Switch Locations

SC.142 110

OM-1584 Page 15

B. DIP Switch Description

1. Digital Meter Functions DIP Switch (Optional)(Figures 4-7 And 4-8)

The digital meter function DIP switches are located on

digital meter circuit board PC6O (see Figure 4-7 for cir

cuit board location). Figure 4-8 shows correct switch po

sitioning for the different modes available. See Section

5-11 for description of a desired mode.

2. Spot Time DIP Switch (Optional) (Figure 4-7)

The spot time DIP switch is located on 4-In-I board

PC3O. The DIP switch comes factory set to operate in

the 0 to 5 second (LONG) range. If it is desired to oper

ate wire feeder in the 0 to 2.5 second range, change DIP

switch to the (SHORT) position. See Section 5-10 for a

description of the control functions.

Inches/Minute

3. Remote Input/Run-In DIP Switch (Optional) (Figures 4-7 And 4-9)

The remote input/run-in DIP switch is located on optioninterface board P070. The DIP switch consists of two

switches, 1 and 2. Both switches come factory set in the

ON position.

Switch 1:

To interface wire feeder with a synergic control, placeswitch I in the OFF position.

For standard use or for use with dual schedule or remote

control, place switch 1 in the ON position.

Switch 2:

For RUN-IN SPEED control with voltage sensing, placeswitch 2 in the ON position.

For RUN-IN SPEED control without voltage sensing,place switch 2 in the OFF position.

Figure 4-8. Digital Meter Functions DIP Switch

U,

C,,

� High Speed Motor

U

U

I

� High Speed Motor

Meters/MInute

I~

Meters/Minute

U

I

I

I

e Moni br

U,

Voltat

be in either position.

� The voltage hold function can be used in conjunction with

the following modes: high speed motor, meters/minute,

and high speed motor-meters/minute.

� � Do not use the high speed motor, or high speed motor-

meters/minute modes unless unit is equipped with a

high speed motor.Ref. S-0399

OM-1584 Pa9e 16

~I :Place Switch Si (1) In The OFF Position For Synergic input.The Position Of Switch Si (2) WIll Not Affect Switch Si (1).

0-nm

r�)

Place Switch Si (2) in The OFF Position For Run-In SpeedControl Without Voltage Sensing. The Position Of Switch

Si (1) WIll Not Affect Switch Si (2).

Place Switch Si (I) in The ON Position For Standard Use

And For Dual Schedule Or Remote Pendant. The Position

Of Switch Si (2) Wili Not Affect Switch Si (1).

0mm

IPlace Switch Si (2) in The ON Position For Run-in SpeedControl With Voltage Sensing. The Position Of Switch Si (i)Will Not Affect Switch Si (2).

S-0360

Figure 4-9. Remote Synergic Input/Run-In Voltage Sense DIP Switch

Motor Control

Receptacles

� OPTIONAL

Figure 4-10. Rear Panel

� Remote

Pendant

SA.142 715

Power Switch

� 5-Pin interconnecting

� Voitage SensingLead

i4-Pln

interconnectingCord

OM-1584 Page 17

4-13. VOLTAGE SENSING CONNECTION (Optional)(Flgure 4.10)

A 35 ft. (12.4 m) voltage sensing lead is provided with

several options. Connect the voltage sensing lead to the

workpiece.

4-14. RUN-IN CONTROL CONNECTIONS (Option.al) (FIgure 4-10)

a ELECTRIC SHOCK can kill.


� Shut down wire feeder and welding powersource anddisconnect inputpoweremployinglockout/tagging procedures before installingreed relay.





When the optional Run-In control is provided, the weld

cable from the boom must be routed through the reed

relay before going to the welding power source. Proceed

as follows:

1. Install the reed relay to the front or rear control

box mounting arm. Holes are provided in the

mounting arms near the boom.

2. Connect the plug from the reed relay to the

matching receptacle on the rear of the control box

as follows: align keyways, insert plug, and rotate

threaded collar fully clockwise.

3. Route the weld cable from the boom, through the

reed relay, and to the welding power source out

put terminal.

4-15. SYNERGIC CONNECTIONS (Optional)

Aloft. (3.1 m) cord can be provided for connections to

the RCSP-45 synergic control. Route the cord from the

wire feeder to the synergic control and make connec

tions as follows: align keyway, insert plug into matchingreceptacle, and rotate threaded collar fully clockwise.

4-16. WELDING WIRE INSTALLATION

A. Installation Of Spool-Type Wire

1. Remove retaining ring.

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

top of spool.

3. Rotate spool until hole in spool aligns with pin in

hub. Slide spool onto hub until it seats againstback flange of the hub.

4. Reinstall retaining ring onto hub.

B. Installation Of Optional Wire Reel And Reel-

Type Wire (Figure 4-11)

1. Remove retaining ring and, if applicable, wire reel

assembly from hub.

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

3. Remove spanner nut from wire reel assembly.

4. Remove wire retainer, and install wire onto wire

reel. Be sure that wire feeds off top of reel.

5. Reinstall wire retainer and spanner nut onto wire

reel.

6. Slide wire reel assembly onto hub, and rotate as

sembly until hub guide pin is seated in reel.

7. Reinstall retaining ring onto hub.

� OPTIONAL SC-143 478

Figure 4-11. Optional Wire Reel And Reel-TypeWire Installation

C. Adjustment Of Hub Tension

Check the hub tension by slowly rotating the wire spoolor reel. The wire should unwind freely, but hub tension

should be sufficient to keep wire taut and prevent back

lash when the wire feed stops. If adjustment is required,loosen or tighten the hex nut on the end of the hub sup

port shaft accordingly.

4-17. SAFETY COLLAR REMOVAL (Figure 4-1)

a WARNING: RELEASE OF SPRING PRES

SURE WITHOUT BOOM ATTACHED can

cause serious personal injury and equipment damage.� Perform installation exactly as outlined in the

following step-by-step instructions.

� Do not remove safety collar until instructed to

do so.

� Retain safety collar for future disassemblyuse.

A safety collar is provided on top of the post to maintain

spring pressure and prevent vertical movement duringinstallation. The collar is required whenever the boom is

disassembled or relocated. To remove the safety collar,

proceed as follows:

� Wire Retainer

7� Spanner Nut

RetainingRIng

OM-1584 Page 18

1. Grasp boom and pull down slightly. The boom

should be pulled down only far enough to remove

the pressure which is applied to the safety collar.

2. Remove the safety collar, and retain for future

use.

3. The boom should now balance in any positionfrom horizontal to 60 degrees above horizontal. If

the boom does not balance properly, proceed to

Section 4-18.

4-18. BOOM ADJUSTMENTS (Figure 4-12)

A. Weight Lift Adjustment

a WARNING: FALLING BOOM can cause seri

ous personal injury and equipment damage.

� Maintain full threads on adjustment rod

through the yoke.

The amount of weight which the boom can retract into

the upright position when released can be varied by ad

justing the jam nut and adjustment rod located at the

base of the boom. If a heavier gun is installed on the end

of the boom making it necessary to increase the amount

of weight that the boom can lift, loosen the jam nut and

rotate the adjustment rod so that the adjustment rod

threads into the yoke. When the proper adjustment is ob

tained, tighten the jam nut against the base of the yoke. If

a lighter gun is used, rotate the adjustment rod so that

the adjustment rod threads out of the yoke.

EFigure 4-12. Boom Adjustments

B. Locking Knob

Yoke

Jam Nut

AdjustmentRod

SA.142 599�A

By rotating the Locking Knob, located on the side of the

swivel plate, in a clockwise direction, the boom may be

held in any desired position. Rotating the Locking Knob

in a counterclockwise direction will permit the boom to

free travel. Changing the position of the Locking Knob to

the other threaded holes provided along the side of the

swivel plate limits the lift of the boom to 50 degrees or 40

degrees respectively during free travel.

4-19. WELDING WIRE THREADING

a WARNING: ELECTRIC SHOCK can kill;MOVING PARTS can cause Injury.� Do not touch live electrical parts.

� Keep away from moving parts.

� Do not energize welding powersource or wire

feeder until instructed to do so.


with it are energized while welding.

WELDING WIRE can cause puncturewounds; HOT SURFACES can burn skin.

� Do not press gun trigger until instructed to do

so.

� Do not point gun toward any part of the body,any conductive surface, or other personnelwhen threading welding wire.

� Allow gun to cool before touching.

a CAUTION: LOOSE WELDING WIRE can

cause Injury.� Keep a firm hold on the wire during installa

tion, removal, and threading operations.-

Spooled wire has a tendency to unravel rapidlywhen loosened from the spool.

1. Install the wire as instructed in Section 4-16.

2. Cut off any portion of the free end of the wire

which is not straight. If necessary, straighten wire

to remove cast. Be sure that the cut end is free

from rough surfaces to permit proper feeding.

3. Adjust hub tension according to Section 4-16C if

necessary.

4. Manually route the wire through the wire guidetube on the side of the boom, over the wire pulley,and to the drive assembly.

5. Lay gun cable assembly out straight (no coils in

the cable/conduit).

6. Energize the welding power source.

7. Place the wire feeder Power switch in the ON

position.

8. Push the JOG switch up (see WARNING block at

beginning of this Section). Wire feeds if drive roll

pressure is properly adjusted to prevent slippage.If wire slippage is noticed, turn pressure adjustment knob clockwise in 1/4 turn increments until

wire slippage stops. If excess pressure is re

quired, check gun contact tube and gun liner for

correct size or obstructions. Release the JOG

switch when welding wire extends approximately1 in. (25 mm) out of gun tip.

9. Shut down wire feeder and welding power

source.

OM-1584 Page 19

4-20. CHANGING FROM STANDARD DIGITAL

VOLTAGE CONTROL TO MILLER INVERTER

DIGITAL VOLTAGE CONTROL




source, and disconnect input power employing lockout/tagging procedures before

making internal adjustments.




ing device.

CAUTION: ELECTROSTATIC DISCHARGE

(ESO) can damage circuit boards.

� Put on properly grounded wrist strap BEFORE handling circuit boards.

� Transport circuit boards in proper static-

shielding carriers or packages.


INCORRECT INSTALLATION or misalignedplugs can damage circuit board.

� Be sure that plugs are properly installed and

aligned.

EXCESSIVE PRESSURE can break circuit

board.

� Use only minimal pressure and gentle movement when disconnecting or connectingboardplugs and removing or installing board.

A. Electrical Connections

When optional Digital Voltage Control is used with a

MILLER inverter-type power source, it is necessary to

make reconnections to digital voltage control board

PC4O. To make reconnections, proceed as follows (seeFigure 4-8 for circuit board location):

1. Remove wrapper.

2. Remove securing hardware from upper left cor

ner of nameplate and side panels, and open

hinged front panel.

3. Disconnect plug PLG82 from receptacle RC42.

4. Connect plug PLG82 to receptacle RC44.

5. Disconnect jumper plug PLG6I from receptacleRC45.

6. Disconnect plug PLG43 or PLG44, as applicable,from receptacle RC41.

7. Connect plug PLG43 or PLG44 to RC45.

8. Connect jumper plug PLG61 to RC41.

9. Close and secure hinged front panel.


B. Digital Meter Recalibratlon

IMPORTANT: If this wire feeder is being used with a

MILLER inverter-type power source that has a voltagerange of 10 to 35 volts in the CV mode, no dig/ta/meterrecalibration is required.

If this wire feeder is being used with a MILLER inverter

type power source that has a voltage of other than 10 to

35 volts in the CV mode, recalibrate the digital meter as

follows:

1. Place the digital meter WIRE SPEEDNOLTAGE

switch in the VOLTAGE position (see Figure 5-1

for switch location).

2. Rotate the SCHEDULE A or B Voltage Control,whichever is active, to the maximum position (see

Figure 5-1 for control location).

3. Remove securing hardware from upper left cor

ner of nameplate and side panels, and open

hinged front panel.



4. Energize the wire feeder.

5. Adjust potentiometer R31 located on PC4O, until

the digital meter displays a voltage equal to the

maximum voltage listed on the AmperageNoltage control of the welding power source

6. Close and secure hinged front panel.

a

This procedure requires the unit to be energized.Only qualified persons familiar with and follow

ing standard safety practices are to perform this

procedure.

OM-1 584 Page 20�

SECTION 5� OPERATOR CONTROLS

�Left Side SCHEDULE A

Voltage Control

Left Side SCHEDULE A

Wire Speed

�Left Side SCHEDULE B

indicator Light


Voltage Control


Wire Speed Controi

Left Sideindicator Light.

Left SideTRIGGER RECEPTACLE

� OPTIONAL

Figure 5-1. Front Panel Controls

�Digital Meter

�WIre Spe.d/

Voltage Switch

Right Side SCHEDULE A

Wire Speed Control

�Right Side SCHEDULE A

Voltage Controi

�Rlght Side SCHEDULE B

Indicator Light

�Right Side SCHEDULE B

Wire Speed Control

�Right Side SCHEDULE B

Voltage Control

Right Side

Indicator Light

Right Side

TRIGGER RECEPTACLE

�Right Side Press To Set

Button LocationSC-142 739-A

5-1. POWER SWITCH (Figure 4-9)

The Power switch is located on the rear panel, and functions as the ON/OFF switch for the wire feeder.

IMPORTANT: This is a dual wire feeder with appropriatecontrols for left and right sides. Most optional controls

can be installed in both sides or only one side.

5-2. WIRE SPEED CONTROLS (Figure 5-1)

oloThe Wire Speed control adjusts the wire feed speed in

inches per minute (1pm) within the wire speed range. Ro

tating the Wire Speed control clockwise increases wire

feed speed. The scale is calibrated in inches per minute

x 100 when used with a single turn potentiometer.

5-3. JOG/PURGE SWITCHES (Figure 5-1)

IPURGE

The JOG/PURGE switch is a three position switch. The

center position is off.

The JOG function is activated by pushing the JOG/

PURGE switch up. When in this position, it permits jogging of the wire at the Wire Speed control setting without

energizing the welding circuit or the shielding gas valve.

The PURGE function is activated by pressing the JOG/

PURGE switch down. When in this position, it acts as a

momentary-contact switch energizing the gas solenoid

and purging the gun shielding gas line, and allows the

shielding gas regulator to be adjusted without energizingthe welding circuit.

�Left Side Press To Set Left Side Right Side

Button Location JOG/PURGE Switch JOG/PURGE Switch

JOG

qjo

OM-1584 Page 21

5-4. VOLTAGE CONTROL(S) (Optional) (Figure5.1)

VThe Voltage control provides a means of setting arc volt

age. Rotating the control clockwise increases arc volt

age. The scale is calibrated 0 to 100 percent when used

with a single turn potentiometer.

5-5. DIGITAL VOLTAGE CONTROL(S) (Optional)(Figure 5-1)

The Digital Voltage Control is a ten-turn potentiometerwhich provides a means of presetting the arc voltage.Rotating the control clockwise increases the arc voltage.

When the optional Digital Voltage Control is used with

MILLER inverter-type welding power sources, the con

trol functions as a remote digital control and allows the

operator to preset arc voltage.

The optional Digital Voltmeter displays the output volt

age to the nearest tenth of a volt. Before the gun trigger is

depressed, the meter displays the preset voltage as set

by the control. When the trigger is depressed, and before

an arc is struck, the meter displays the welding power

source open-circuit voltage. After an arc is struck, the

meter displays actual voltage.

5-6. BURNBACK CONTROL(S) (Optional) (Figure5-2)

The burnback circuitry in this control keeps the weldingwire from sticking to the workpiece after the gun trigger is

released. The burnback capability in this wire feeder

keeps weld output present on the welding wire from 0 to

0.25 seconds after the wire has stopped feeding, de

pending on the setting of the Burnback control. This

delay action permits the welding wire to burn back to a

point where it neither sticks to the workpiece nor the con

tact tube. If the welding wire sticks to the workpiece, ro

tate the BURNBACK control clockwise.

5-7. PREFLOW CONTROL(S) (Optional) (Figure5-2)

When the gun trigger is closed the PREFLOW control

provides 0 to 5 seconds of gas flow before the weld out

put contactor and wire drive motor are energized. The

scale is calibrated in seconds. Rotating the control

clockwise increases the length of time gas flows.

5-8. POSTFLOW CONTROL(S) (Optional) (Figure5-2)

The POSTFLOW control provides 0 to 5 seconds of gasflow after completion of the BURNBACK cycle. The

scale is calibrated in seconds. Rotating the control

clockwise increases the length of time gas flows.

5-9. TRIGGER HOLD SWITCH(ES) (Optional)(Figure 5-1)

The TRIGGER HOLD function allows the operator to

continually feed wire without holding in the gun trigger.To use TRIGGER HOLD, place TRIGGER HOLD switch

in the up position. Making momentary contact with the

gun trigger while the switch is in the up position will acti

vate the TRIGGER HOLD function. After the PREFLOW

cycle has timed out, wire will continue to feed until the

gun trigger is again depressed, thereby terminatingTRIGGER HOLD. After TRIGGER HOLD is terminated,BURNBACK and then POSTFLOW circuitry will begin to

time out.

The TRIGGER HOLD function is inoperable while unit is

in the SPOT mode.

S8-143 878

Figure 5-2. Inner Control Panel (Right Or Left Side)

TRIGGERHOLD SPOT

CONTINUOUS

PREFLOW 2 SPOT 3

150:4BURNBACK

.050.2POSTFLOW

0

OM-1584 Page 22

5-10. SPOT/CONTINUOUS SWITCH(ES) AND

SPOT TIME CONTROL(S) (Optional) (Figure5-2)

When the SPOT/CONTINUOUS switch is in the CON

TINUOUS position, the circuitry provides continuous

welding capability after the PREFLOW cycle has timed

out. When the gun trigger is released, BURNBACK, and

then POSTFLOW circuitry begin to time out.

If it is desired to use wire feeder in the SPOT mode, placethe SPOT/CONTINUOUS switch in the SPOT position.Two ranges of SPOT control time are available

,0 to 2.5,

or 0 to 5 seconds (see IMPORTANT Block for informa

tion on changing SPOT control time range). Rotating the

SPOT control dial clockwise increases SPOT time.

IMPORTANT: This wire feeder comes factory set to op

erate in the 0 to 5 second range. If required to operateunit in the 0 to 2.5 second range, see Section 4-12 for in

structions on how to change DIP switch position.

After the PREFLOW cycle has timed out, the spot weld

timer begins to time out the selected period of time set on

the SPOT time control. When the time set on the SPOT

time control has elapsed, or the trigger is released,

BURNBACK, and then POSTFLOW timer circuitry be

gin to time out.

5-11. DIGITAL METER (Optional) (Figure 5-1)

olo /vBy placing the Wire SpeedNoltage switch in the Voltageposition, the meter functions as a weld voltage meter.

The voltmeter is connected to the welding circuit bymeans of the wire drive assembly and the voltage sense

clamp at the workpiece. The voltmeter indicates the dc

voltage at the wire feeder and will vary slightly from actual arc voltage due to cable resistance, poor connec

tions, etc.

The unit comes factory set to operate in the VoltageHold/Inches Per Minute mode. While in the VoltageHold/Inches Per Minute mode, the meter holds the dis

play as follows: approximately 5 seconds after the trigger is pulled, the circuitry will automatically hold the volt

age value displayed at that time. This value will be main

tained on the meter display for the duration of the weld

and approximately 15 seconds after the trigger is re

leased. When the 15 seconds have elapsed, the meter

will clear to actual power source output (zero volts, or

open-circuit voltage, if present). Repulling the trigger before the 15 seconds has elapsed resets the meter to read

arc voltage, after 5 seconds it will then automaticallyhold the voltage value displayed at that time.

If desired, the digital meter functions DIP switches (seeSection 4-12) can be positioned to operate meter in the

Voltage Monitor mode. While in the Voltage Monitor

mode the meter will continuously display the existingvoltage values of the welding operation. When the arc is

broken, the meter will display zero volts (or open circuit

voltage, if present).

By placing the Wire SpeedNoltage switch in the Wire

Speed position, the meter functions as a wire speed meter.

The unit comes factory set to operate in the VoltageHold/Inches Per Minute mode which displays the rate of

wire feed in inches per minute (50 to 790 ipm). If desired,the unit can be operated in the Meters/Minute mode

which displays the rate of wire feed in meters per minute

(1.3 to 20.3 mpm). See Section 4-12 for instructions on

changing DIP switches.

If the unit is equipped with a high speed motor, the DIP

switches come factory set to operate in the High SpeedMotor mode which displays the rate of wire feed for the

high speed motor (90 to 1470 ipm), or if desired, the DIP

switches can be positioned in the High Speed Motor Me

ters/Minute mode to display high speed motor wire feed

speed in meters per minute (2.3 to 37.3 mpm). To

change DIP switches, see Section 4-12.

5-12. RUN-IN CONTROL(S) (Optional) (FIgure 5-2)

The RUN-IN SPEED control provides a means of select

ing the rate at which welding wire will feed after preflowand before arc initiation. After arc initiation, the wire feed

speed is governed by the Wire Speed control. Duringrun-in, the selected RUN-IN SPEED will be displayed bythe Wire Speed Meter if unit is so equipped. Rotating the

RUN-IN SPEED control clockwise will increase wire

feed speed. The RUN-IN SPEED scale is calibrated in

inches per minute.

IMPORTANT: Unit is equipped with a Remote Input!Run-In Voltage Sense DIP switch located on option in

terface circuit board PC7O. The DIP switch Si consists

of two switches, (1) and (2). Both switches come factoryset in the ON position.For RUN-IN SPEED control with voltage sensing, placeswitch SI (2) in the ON position (see Section 4- 12B).For RUN-IN SPEED control without voltage sensing,place switch Si (2) in the OFF position (see Section

4-128).

5-13. DUAL SCHEDULE CONTROL(S) (Optional)(Figure 5-1)

olo V

The Dual Schedule controls allow the use of two weldingschedules (A dual schedule switch is required for use

with this option, but is not provided. Obtain a proper dual

schedule switch, and install switch according to its in

structions.)

The SCHEDULE A and B Wire Speed controls are one

turn potentiometers which are used to set wire speed.SCHEDULE A or SCHEDULE B Wire Speed control will

be active depending on the position of the dual schedule

switch. When SCHEDULE B is active, SCHEDULE B in-

OM-1584 Page 23

dicator light will be illuminated. When the indicator lightis off, SCHEDULE A is selected. Rotating the dial clock

wise increases wire feed speed.

The SCHEDULE A and B Voltage controls are one-turn

potentiometers which are used to set arc voltage.SCHEDULE A or SCHEDULE B Voltage control will be

active depending on theposition of the dual schedule

switch. When SCHEDULE B is active, SCHEDULE Bin

dicator light will be illuminated. When the indicator lightis off, SCHEDULE A is selected. Rotating the dial clock

wise increases voltage.

5-14. DIGITAL DUAL SCHEDULE CONTROL(S)(Optional) (Figure 5-1)

olo V

The Digital Dual Schedule controls allow the use of two

welding schedules, (A dual schedule switch is requiredfor use with this option, but is not provided. Obtain a

proper dual schedule switch, and install switch accord

ing to its instructions.)

The SCHEDULE A and B Wire Speed controls are ten-

turn potentiometers which are used to set wire speed.SCHEDULE A or SCHEDULE B Wire Speed control will

be active depending on the position of the dual schedule

switch. When SCHEDULE B is active, SCHEDULE B in

dicator light will be illuminated. When the indicator lightis off, SCHEDULE A is selected.

Placing the Wire SpeedNoltage switch in the Wire

Speed position allows the meter to function as a wire

speed meter. The meter will display wire feed speed for

SCHEDULE A or SCHEDULE B, depending on the position of the dual schedule switch.

The SCHEDULE A and B Voltage controls are ten-turn

potentiometers which are used to set arc voltage.SCHEDULE A or SCHEDULE B Voltage control will be

active depending on the position of the dual schedule

switch. When SCHEDULE B is active, SCHEDULE B in

dicator light will be illuminated. When the indicator lightis off, SCHEDULE A is selected.

Placing the Wire SpeedNoltage switch in the Voltageposition allows the meter to function as a voltage meter.

The meter will display voltage for SCHEDULE A or

SCHEDULE B, depending on the position of the dual

schedule switch. Before the gun trigger is depressed,the meter will display the preset value. When the triggeris depressed, and before and arc is struck, the meter dis

plays the welding power source open-circuit voltage. After an arc is struck, the meter displays dc voltage at the

wire feeder, which will vary slightly from actual arc volt

age due to cable resistance, poor connections, etc. The

meter will display voltage to the nearest tenth of a volt.

PRESS TO SET buttons allows the operator to presetSCHEDULE B voltsge and/or wire feed speed while in

SCHEDULE A. To preset left side SCHEDULE B voltageand/or wire feed speed, depress left side PRESS TO

SET button, and adjust control(s), follow the same pro

cedure to preset right side SCHEDULE B voltage and/or

wire feed speed.

SECTION 6� SEQUENCE OF OPERATION

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

FLUX CORED ARC WELDING (FCAW)

a WARNING: ELECTRIC SHOCK can kill;MOVING PARTS can cause serious injury;EXPOSURE TO ENVIRONMENT can damageInternal parts.� Do not touch live electrical parts.


� Keep case closed while operating.

Warranty is void if the wire feeder is operatedwith any portion of the outer enclosure open or

removed.

ARC RAYS, SPARKS, AND HOT SURFACES

can burn eyes and skin; NOISE can damagehearing.� Wear correct eye, ear, and body protection.

FUMES AND GASES can seriously harm

your health.

� Keep your head out of the fumes.

� Ventilate to keep from breathing fumes and

gases.

� If ventilation is inadequate, use approvedbreathing device.

HOT METAL, SPATTER, AND SLAG can

cause fire and burns.

� Watch for fire.

� Keep a fire extinguisher nearby, and know

how to use it.

� Do not use near flammable materials.

� Allow work and equipment to cool before

handling.MAGNETIC FIELDS FROM HIGH CURRENTS

can affect pacemaker operation.� Wearers should consult their doctor before

going near arc welding, gouging, or spot welding operations.

WELDING WIRE can cause puncturewounds.

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

See Section 1 - Safety Rules For Operation Of

Arc Welding Power Source for basic weldingsafety information.

Install and connect unit according to Section 4.

2. Energize the welding power source.

3. Place the Power switch in the ON position.

OM-1 584 Page 24

4. Rotate Wire Speed control to the desired position

(see Section 5-2).

5. Wear dry insulating gloves and clothing.

6. Connect work clamp to clean, bare metal at work-

piece.

7. Select and obtain proper welding wire, and thread

as instructed in Section 4-19.

8. Turn on shielding gas at the source, if applicable.

9. Press PURGE switch down for one minute, if

applicable.

10. Wear welding helmet with proper filter lens ac

cording to ANSI Z49.1.

11. Hold the tip of the gun approximately 1/2 in. (13

mm) from the workpiece.



� Do not touch electrode wire when gun triggeris pressed.


with it carry weld output when the welding powersource contactor is energized.

12. Press the gun trigger. Gas flows and wire feeds if

drive roll pressure is properly adjusted to prevent

slippage. If wire slippage is noticed, adjust drive

roll pressure according to Section 4-6C.

6-2. SHUTTING DOWN

1. Stop welding.

2. Place Power switch in the OFF position.

3. Shut down the welding power source or genera

tor.

4. Turn off shielding gas at source, if applicable.

a WARNING: HIGH CONCENTRATION OF

SHIELDING GAS can harm health or kill.

� Shut off gas supply when not in use.

SECTION 7� MAINTENANCE & TROUBLESHOOTING

7-1. ROUTINE MAINTENANCE (Table 7-1)

IMPORTANT: Every six months inspect the labels on

this unit for legibility. All precautionary labels must be

maintained in a clearly readable state and replacedwhen necessary. See Parts List for part number ofpre

cautionary labels.




source, and disconnect input power employing lockout/tagging procedures before in

specting, maintaining, or servicing.

Lockout/tagging procedures for wire feeder con

sist of disconnecting interconnecting cord, and

for welding power source consist of padlockingline disconnect switch in open position, remov

ing fuses from fuse box, or shutting off and red-

tagging circuit breaker or other disconnectingdevice. Stop engine, and disconnect negative(�) battery cable from battery on weldinggenerators.

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

HOT SURFACES can cause severe burns.

� Allow cooling period before servicing.

Maintenance to be performed only by qualifiedpersons.

Table 7-1. Maintenance Schedule

Frequency* Maintenance

Every Month Units in heavy service environ

ments:

Check labels, hoses, and cables;clean internal parts and drive

rolls.

Every 6 Months Check all labels (see IMPORTANT block, Section 7-1). Inspectgun and cables (Section 7-1 B).Clean drive rolls (Section 7-iC).

*Frequency of service is based on units operated 40

hours per week. Increase frequency of maintenance if

usage exceeds 40 hours per week.

A. Internal Cleaning

a WARNING: Read and follow safety informa

tion at beginning of entire Section 7-1 before

proceedIng.

Every six months, blow out or vacuum dust and dirt from

the inside of the wire feeder. Remove the outer enclo

sure, and use a clean, dry airstream or vacuum suction

for the cleaning operation. If dusty or dirty conditions are

present, clean the unit monthly.

B. InspectIon And Upkeep

a WARNING: Read and follow safety Information at beginning of entire Section 7-1 before

proceedIng.

OM-1584 Page 25

Every six months, inspect the gun, hoses, and cables. If

dusty or dirty conditions are present, inspect the unit

monthly. Inspection should consist of the following:

1. Inspect gun for broken areas, cracks, and loose

parts; tighten, repair, and replace as required.

2. Repair or replace, as required, all hose and cable;

give particular attention to frayed and cracked in

sulation and areas where hose and cables enter

equipment.

3. Remove grease and grime from components,moisture from electrical parts and cable.

a CAUTION: FLYING DIRT AND METAL PARTI

CLES can injure personnel and damageequipment.� Point gun liner only in a safe direction away

frompersonnel and equipment when cleaningwith compressed air.

4. Blow out the gun wire guide liner with com

pressed air when changing wire. This will remove

any metal chips and dirt that may have accumu

lated.

It is necessary to remove the drive rolls for proper clean

ing of the wire grooves (see Section 4-6B for removal

and installation instructions). Use a wire brush to clean

rolls.

IMPORTANT: Failure to properly maintain the drive rolls

can result in a buildup of wire particles which decreases

the efficiency of the wire feeding operation.

7-2. REINSTALLATION OF HUB ASSEMBLY (Figure 7-1)






Lockout/tagging procedures for wire feeder consist of disconnecting interconnecting cord, and

for welding power source consist of padlockingline disconnect switch in open position, removing fuses from fuse box, or shutting off and red-

tagging circuit breaker or other disconnectingdevice.

C. Cleaning Of Drive Rolls

a WARNING: Read and follow safety information at beginning of entire Section 7-1 before

proceeding.

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

HIGH ROTATIONAL SPEED may cause dam

age to drive rolls and injure personnel.

If it becomes necessary to replace any part of the as

sembly, obtain part and proceed as follows to reinstall

the assembly.

1. Remove hub assembly from hub support and dis

assemble, discarding worn or broken parts.

2. Slide the following items onto the hub supportshaft in order given:

a. Fiber Washer

b. Brake Washer

Fiber Washer

Keyed Washer

SpringFlat Washer

Nut Retaining Ring

SB-142 109

Figure 7-1. Reinstallatlon Of Hub Assembly

� Do not allow drive rolls to rotate at high speedifcompressed air is used for cleaning the drive

roll assembly.

Fiber Washer

Washer

Hub

Brake Washer

OM-1 584 Page 26

c. Hub

d. Brake Washer

e. Fiber Washer

f. Keyed Washer

g. Spring

h. Flat Washer

3. Install hex nut onto hub support shaft. Tighten hex

nut until a slight drag is felt white turning hub.

4. Install welding wire according to 4-16.

7-3. BRUSH INSPECTION AND REPLACEMENT

(Figure 7-2)









CAUTION: DISASSEMBLY OF THE MOTOR

FIELD MAGNETS can result in personal in

jury and equipment damage.

� Limit drive motor repairs to brush replacement.

The field magnets are very strong. If disassem

bly is attempted, injury to fingers and hands mayresult from the rotor being drawn back into the

motor. The field magnets are matched sets, and

operation may be affected if the magnets are

tampered with. Warranty is void if the motor is

tampered with.

Remove the two brush caps.

2. Remove brushes.

3. Examine brushes. Replace brushes if they be

come chipped or broken or if less than 1/4 in. (6.4

mm) of brush material is left. Do not include the

spring boss as part of the 1/4 in. measurement.

4. Install brushes, and secure with caps.











IMPROPER FUSE can damage unit.

� Be sure replacement fuse is same size, type,and rating (see Parts List).

A. Circuit Breaker CB1 (Figure 5-2)

a WARNING: Read and follow safety information at beginnIng of entire SectIon 7-4 before

proceeding.

Circuit breaker CB1 provides protection to the feeder

motor. CB1 is located on the inner control panel behind

the left side access door (see Figure 5-2). If the motor

should overload, the breaker would trip and shut down

the wire feeder.

Should a motor overload occur and trip CB1, proceed as

follows:

1. Check for jammed wire or clogged gun liner, and

correct problem. If motor overload happens often,

repair or replace the motor or liner.

2. Check for binding drive gear or misaligned drive

rolls, and correct problem.

Cape (2)

f~ WARNING: ELECTRIC SHOCK can kill.

_____ . Do not touch live electrical parts.

Motor End Cap

SA.137 390�A

Figure 7-2. Brush Inspection And Replacement

7-4. OVERLOAD PROTECTION

OM-1584 Page 27

3. Manually reset CB1; it may be necessary to allow

a cooling period before the breaker can be reset.

4. Resume operation.

B. Fuse For Optional RCSP-45 Connection

a WARNING: Read and follow safety information at beginning of entire Section 7-4 before

proceeding.

When this unit is equipped with the optional cord for con

nection to the RCSP-45 Synergic Control, a fuse is add

ed into the wiring harness in the unit. Should this fuse

open, the RCSP-45 would not work. To replace the fuse,

proceed as follows:

1. Remove wrapper.

2. Locate fuse in wiring harness.

3. Grasp halves of fuse holder and twist counter

clockwise to open.

4. Check and replace fuse.

5. Twist fuse holder halves clockwise to secure.


7-5. CIRCUIT BOARD HANDLING PRECAUTIONS

ft_ WARNING: ELECTRIC SHOCK can kill.


a









CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit board components.

� Put on properly grounded wrist strapBEFORE handling circuit boards.

� Transport all static-sensitive components in

proper static-shielding carriers or packages.


INCORRECT INSTALLATION or misalignedplugs can damage circuit board.

� Be sure that plugs are properly installed and

aligned.

EXCESSIVE PRESSURE can break circuit

board.

� Use only minimal pressure and gentle movement when disconnecting or connectingboard plugs and removing or installing board.

7-6. TROUBLESHOOTING (Table 7-2)








for welding power source consist of padlockingline disconnect switch in open position, removing fuses from fuse box, or shutting off and red-


MOVING PARTS can cause serious injury.


HOT SURFACES can cause severe burns.

� Allow cooling period before servicing.

Troubleshooting to be performed only by qualified persons.

It is assumed that the unit was properly installed accord

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

with the function of controls, the wire feeder was working

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

process.

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

this wire feeder. Use this table in conjunction with the cir

cuit diagram while performing troubleshooting proce

dures. If the trouble is not remedied after performingthese procedures, the nearest Factory Authorized Serv

ice Station should be contacted. In all cases of equipment malfunction, the manufacturer�s recommenda

tions should be strictly followed.

IMPORTANT: Ensure that all connections to the feeder

and welding power source are secure and that all

switches are in the proper position for the welding applications before beginning troubleshooting procedures.

OM-1584 Page 28

Table 7-2. Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Wire feeds, shielding gas flows,but electrode wire is not ener-

gized.

Contactor control connection

(Interconnecting cord).

Check interconnecting cord connections. If se

cure, check cord for continuity and repair or re

place.

Welding power source. See Troubleshooting Section in welding powersource Owner�s Manual.

Wire does not feed. Circuit breaker CB1. Reset CB1 (see Section 7-4).

Loose or improperly made gun

trigger connection

Check gun trigger connection (see Section 4-7).

Gun Trigger. See gun Owner�s Manual.

Motor. Replace motor.

Motor control board PCi. See Section 7-5 and contact nearest Factory Authorized Service Station.

Wire feeds erratically. Pressure on drive rolls is insuffi-

cient.

Rotate pressure adjustment knob clockwise in

1/4 turn increments until the wire stops slipping(see Section 6-1).

Drive rolls wrong size for wire

size used.Change to correct size drive roll (see Section

4-6).

Drive rolls worn. Replace drive rolls (see Section 4-6B).

Dirt in drive rolls. Clean drive rolls (see Section 7-iC).

Incorrect size contact tube or

liner.

Check and replace necessary parts.

Obstruction in gun contact tube

or liner.

Clear obstruction in gun contact tube or gun liner.

Motor control board PCi. See Section 7-5, and contact nearest FactoryAuthorized Service Station.

Motor runs slowly. Low line voltage. Correct low line voltage.

Obstruction in gun contact tube

or liner.

Clear obstruction in gun contact tube or gun liner.

Gun nozzle opening restricted. Weld spatter or foreign matter

accumulation.Carefully remove any weld spatter or foreignmatter which may accumulate around the nozzle

opening. Use a hardwood stick, never a metal

tool.

Wire does not feed until triggeris pulled, but continues to feed

after trigger is released, and

trigger hold is not on.

Welding gun is shorted be-

tween one of the trigger leads

and weld cable.

Replace welding gun.

The gas valve in the feeder is

rattling loudly along with possi-ble erratic or slow wire feed

speed.

Welding gun is shorted be-

tween one of the trigger leads

and weld cable.

Replace welding gun.

Unit does not switch out of

RUN-IN-SPEED.

Unit is not receiving current

sensing or voltage sensingsignal.

Install, reconnect, or replace reed relay or volt

age sensing leads.

Wire feeder power is on, meter

lights up, but unit is inoperable.Trigger lead is open. Replace welding gun.

4-In-i circuit board PC3O. Turn off power to unit for 30 seconds. Turn power

back on to reset unit.

OM-1584 Page 29

NOTES

OM-1 584 Page 30

PCI

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CircuitDiagramNo.

SC-142857-B

Diagram8-1.

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Wire

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V~TAGE SEP~E 12

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40

OM-1584 Page 32

Diagram 8-2. Circuit Diagram For Wire Feeder With Optional Equipment

TRIGGER ~CONY

;9c1~ PLJRPC6CRI BOARD

SPOT� IOPTIONA1_)

_________

I P01 �P1031IIPIONTI

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__________

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Circuit Diagram No. SD-i 42 858-C

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OM-1 584 Page 33

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121 ~.,M-7)

PLC 12

I ABCIPIGSI-3) I~t~1?4r

WIlTIllI)

cLAN)) PLCI IJ~lSC)PLGII-5)

2F)PLGJ I�i)

LEFT

!REX(

8.U/21K)PLG2~-2)

I~N)PLG28-II

--

RLK)P1028-S)

BPtl)PL028-6)

PLC27

V~l 121 It1~-7l

LEFT

Il-B)

PIGIITBUSSAP

RIGHT

1~)6 ~U/Bu()PLG3a-21

~N)PLG38-I I)

RED/RIX (P1038-3]

~N)Pt.G3O-6(

PLG37

OM-1 584 Page 34

Diagram 8-3. Wiring Diagram For Wire Feeder

~4(CI-C21(

~l9I0

2A(PLG6-4)�

IOA(P166-2)U)

OAD(C2

I�.

~

___________ IR(P1G6-I

~~

35A(PLG6-3

II

I-)

8

nm

11

~

H

284(101

-cGH)(~J1717A(ICE

3~8(PLG94-I6

___________

RED

-u

~

(C(~O

___________

______________

(

rC)

40A)P1G94-9�

~

AC(P1G94-4

C)

I-n

35O)PLG~~

25A)P1GI-

3DE(PLGI-7

___________

RIGHT

2RA(PLGI-

I-

C,JC~) (,J

___________

164(P1694-

IRA

( 198)P1G94-141

II~1~j~7AIP1~4-6i-u;u I_n G~)

(~)I�)

32A(PLG53-2-~

3-34(PLGR3--5)

I

OC(PLGDO-3) 3~C)PL093-I��

�~

34A(P1053-4(

-u

___________________

C,

-u-u IC) 001 (JI

27A(PLG9R-5~

loc(R2-cc~

�

88(R2-CW)

22A(PLGD4-5) ~A(PLG54-41

~

-u C-)

n.

~-o

I~-~-I--Jg

L~l~

C)

L2L~

(ii

~I~l9IQI~~

____

~i~ji�

L~l~I~I~i~k1~I~

001 01O~ 0�

(1)0

.

0�I o

o orn�I 1-4(J) o

ni zz >0) 1rn I

IB(~I-AC)

1~~JWI-

2A

1W

I-AC)

-~-u-u,,-_~I)

C)

�:r~JiCi

0�

-~I0�

a

�

U

�

�

-o I C~)

4�

-u

7

I

~

Ci -J

0

�/0

~

/

rob

U :1 A0

419 Ua 9

~0I C~) �0

C) (,1 0

I

U)

C-)

�

~

I

0 Ui -u C.) a)

(I) mC,-I 0z CD -IU) r Cl)-I

1

Fig9-3

2

456

10

18 19

Fig9-4

33

15~3 20

1 21

3231

3029

28

14.

26

25

24

23

22

SD-142305-D

27

�

Fig9-5

Figure9-1.

Main

Assembly

1.149251

1.149252

PLG23,25..

079 878

079535

079531

605156

PLG24,26..

080 328

079 534

SeeNote

139597

139598

PLG28,38. .

047 636

079 535

079739

135304

PLG27,37..

135409

114656

139600

139599

010603

010606

603106

056112

000950

..6 600323

7... REED... �140789

..8 079531

9.PLG7O,80 ..

079 878

079 535

10 080947

11 601965

12 602213

13 Fig9-214 ��149838

14 ��149 839

14 ��078264

14 ��079 216

15 ��075078

15 ��079217

16 Fig9-417 605227

18..

GS1,2.... 125785

19 PLG51,57 ..131 203

114656

20 PLG11,17..

115092

113746

�21 146544

22 139813

�23 034116

24 146545

25 145639

26.. M1,2 132831

27 Fig9-528 139593

QuantityModel

12 I 16

CABLE, trigger (consisting of) 2

CABLE, trigger (consisting of) 2

HOUSING PLUG & PINS, (consisting of) 1..

I

TERMINAL, male 1 pin 18-14 wire 4. .

4

CLAMP~ cable strain relief sz 11 2..

2

CABLE, port No.184/c (order byft) l7ft 2lft

RECEPTACLE w/SOCKETS, free hanging (consisting of) 1..

1

TERMINAL, female lskt 18-14 wire 4..

4

CONTROL BOX, (Fig 9-3) 1..

1

CABLE, interconnecting (consisting of) 2

CABLE, interconnecting (consisting of) 2

HOUSING PLUG & PINS, (consisting of) 1 .: 1

TERMINAL, male 1 pin 18-14 wire 14.

14

CLAMP, cable strain relief sz 17 1. .

1

CABLE, port No. 18 8/c (order by ft) 16ff 20ff

HOUSING PLUG & SOCKETS, (consisting of) 1..

1


8

HOSE, gas (consisting of) 2

HOSE, gas (consisting of) 2

FITTING, hose brs barbed nipple 1/4tbg 2..

2

FITTING, hose brs nut .625-18RH 2..

2

HOSE, nprn brd No. 1 x .250 ID (order by ff) 26ff 30ff

FITTING, hose brs ferrule .475 ID x .718 Ig 2..

2

FITTING, hose brs coupler .625-18RH/.625-18RH 2..

2

CABLE, weld cop strd No. 3/0 (order by ft) 26ff 30ff

SWITCH, reed (consisting of) 2..

2

CLAMP, cable strain relief sz 11 1..

1


1


4

BRACKET, spring retaining 1. .

1

SCREW, cap stl hexhd .375-16 x 1.000 Ig 4..

4

WASHER, lock stl split .375 4..

4

SUPPORT~ hub & reel 1..

1

PIPE POST, 4ff w/base or 1

PIPE POST, 6ff w/base 1

PIPE POST, 4ff w/base or 1

PIPE POST~ 6ff w/base 1

PIPE POS1 4ff w/o base or 1..

1

PIPE POST, 6ff w/o base I..

1

BOOM ASSEMBLY 1..

1

NUT, nyl hex jam .75ONPST 2..

2

VALVE, 24VAC 2 way custom port 1/8 orf 2..

2


2

TERMINAL, male 1 pin 24-18 wire 3..

3

HOUSING PLUG & SOCKETS, (consisting of) 2.. 2

TERMINAL, female lskt 24-18 wire 8..

8

CLAMP~ motor top 2..

2

COVER, protector motor 1..

1

CLAMP~ stl cush .625dia x .468mtg hole 2..

2

CLAMP, motor base 2..

2

STRIP, buna N compressed sheet .062 x 4.000sq 2..

2

MOTOR, gear 1/8hp 24VDC 272RPM 2..

2

WIRE DRIVE ASSEMBLY 2.. 2

SUPPORT, inlet 2.. 2

CM-I 584 Page 37

Item Dia.

No. Mkgs.PartNo. Description

Figure 9-1. Main Assembly

Note: When ordering Control Box contact factory service department for proper number.

�Part of Optional 132 131 Run-In Control RH/i 38 530 Run-In Control LH

��OPTIONAL

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

Quantity

Model

12 I 16

Item Dia.No. Mkgs.

PartNo. Description

�29

�30

31

�32

�33

Figure 9-1. Main Assembly (Continued)

602 177�.

SCREW, set stl sch .250-20 x .25Oknr cup point 2..

2

146 800..

BUSHING, insulator 2..

2

139 591�. GUIDE, wire inlet 2

�.2

604 612�.

SCREW, set stl sch 8-32 x .125 cup point 2�.

2

082 050..

LINER, monocoil inlet wire 2�.

2

OM-1584 Page 38

Description Quantity

Figure 9-2. Support, Hub & Reel (Fig 9-1 Item 13)

� OPTIONAL


Item Part

No.

1 058 427..

RING, retaining spool 2

2 136 684..

NUT, stl sfflkg hex reg .625-11 w/nyl insert 2

3 605941.. WASHER,flatstl.640lDx1.0000Dxl4gathk .

2

4 010 233..

SPRING, cprsn .97000 x .120 wire x 1.250....

2

5 057 971..

WASHER, flat sti keyed 1 .500dia x .1 25thk 2

6 010191..

WASHER,fbr.65610x1.5000Dx.l25thk 4

7 058 628..

WASHER, brake stl 4

8 058428.. HUB, spool 2

9 080 393..

SUPPORT, reel 1

10 �108 008..

REEL, wire 60 lb (consisting of) 2

11 124 900. . ..

SUPPORT, reel spool 1

12 124 905.. .. RETAINER, spool support 1

13 124904.... NUT,spannerspoolsupport 1

1

5

10

87

6

9

Figure 9-2. Support, Hub & Reel

SC-08t 760

OM-1 584 Page 39

1

Fig9-7

SC-142307

2

3

4

4

21136536_~~35~

22

24

23

28

2

6

29

30

27

F1g9-6�33

32

Figure9-3.

ControlBox

Figure 9-3. Control Box (Fig 9-1 Item 2)

item Dia.

No. Mkgs.Part

No. Description Quantity

3

6

2

3

�

1 140 010..

PANEL, side lower 1

2 PLG1,29,39,53,95

.. ..115 092

..HOUSING PLUG & SOCKETS, (consisting of) 5

113746. . . . TERMINAL, female lskt24-l8wire 8

3.... PC2....

134 994..

CIRCUIT CARD, tach jumper 1

3...

PC5O...

�132 370..

CIRCUIT CARD, tach converter 1

PLG51,57 .�131 203

..HOUSING PLUG & SOCKETS, (consisting of) 1

114 656. . .. TERMINAL, male 1 pin 24-18 wire 3

4. PLG2,54,93 .

115 093..

HOUSING PLUG & SOCKETS, (consisting of)113 746

. . .. TERMINAL, female lskt 24-18 wire

5. PLG56,96 ..

131 204..

HOUSING PLUG & SOCKETS, (consisting of)113 746

. . .. TERMINAL, female lskt 24-18 wire

6.PLG12,18

..135 409

..

HOUSING PLUG & SOCKETS, (consisting of) 2

114 656. . . . TERMINAL, male 1 pin 24-18 wire 8

7.. RC7O,80 ��048 282

..RECEPTACLE w/SOCKETS, (consisting of) 2

079534. . . . TERMINAL, female lskt 18-l4wire 4

8. .

RC3O,40... 047 637..

HOUSING RECEPTACLE & SOCKETS, (consisting of) 2

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

....14

9 139 231..

CASE SECTION, bottom/rear 1

.10

�.PLG4

....115 091

..HOUSING PLUG & SOCKETS, (consisting of) . . . .

1


. ..10

.11

.PLG3,99... 115 094

..HOUSING PLUG & SOCKETS, (consisting of) . .. .

2


. . . .4

.

12..

PLG5....

130 203..

HOUSING PLUG & SOCKETS, (consisting of) . .. .

1

113746. . . . TERMINAL, female lskt 24-18 wire

. . .

12

.13

..PLG6

....136810

..HOUSING PLUG & SOCKETS, (consisting of)


.14

...PCi

....131 818

..CIRCUIT CARD, motor control

.15 089 899

.. LATCH, slide flush

.16 140008

..

WRAPPER

134 464. . LABEL, warning general precautionary

.

17...

CB1....

083 432..

CIRCUIT BREAKER, man reset 1 P 1 OA 250V

.18

...Si 111 997

..SWITCH, rocker SPST 1OA 25OVAC

.19 010 325

..BUSHING, strain relief .840 ID x .875mtg hole

.20 110 015

..CABLE, port No. 18 7/c (order by ft)

.21 079 739

..CLAMP, cable strain relief sz 17

.22

..PLG1O

...141 162

..HOUSING PLUG & PINS, (consisting of)

134 731. . ..

TERMINAL, male 1 pin 18-14 wire

PLG19...

052 309�.

HOUSING, term plug nyl lcont female 1

009418. .

TERMINAL, female lskt 20-14 wire 1

PLG75...

131 204..


113 746. . .. TERMINAL, female lskt 24-18 wire 3

��132 131. .

RUN-IN CONTROL, RH (consisting of) 1

��138 530..

RUN-IN CONTROL, LH (consisting of) 1

.23 601 222

. . ..CLAMP, univ 50A 1

.24 603 106

. . ..HOSE, nprn brd No. 1 x .250 ID (order by ft) lft

.25 600 399

. . ..WIRE, lead mot l4ga (order by ft)

.26 138 044

. . ..BUSHING, strain relief .120/.150 ID x .500mtg hole

C61....

147 853. . ..

CAPACITOR

R71/81...

121 771. . ..

POTENTIOMETER, c sltd sft 1/1 1W 10K ohm

R77/87...

115 093. . ..

HOUSING PLUG & SOCKETS, (consisting of)113746 TERMINAL,female lskt24-l8wire 6

048 144. . . . TERMINAL, male 1 pin plug keying 1

.23 �601 222

..CLAMP, univ 50A

.24 �603 106

..HOSE, nprn brd No. 1 x .250 ID (order by ft)

.25 �600 399

.. WIRE, lead mot i4ga (order by ft)

.26 �138 044

..BUSHING, strain relief .120/150 ID x .500mtg hole

1

4

1

1

1

1

1

1

lift

14

35ft

ift

35ft

OM.1584 Page 41

Figure 9-3. Control Box (Fig 9-1 Item 2) (Continued)

�Part of Optional 138 544 Digital Meter wfrach Feedback

��Part of Optional 132 131 Run-In Control RH/i 38 530 Run-In Control LH

�� OPTIONAL

÷Not part of Control Box AssemblyBE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Item Dia.

No. Mkgs.PartNo. Description Quantity

.27 134201

..STAND-OFF SUPPORT, PC card .312 12

.

28.. Ci,2

. . . .

147 856..

CAPACITOR ASSEMBLY 1

.29

...SRi

... .035 704

..RECTIFIER, integ 40A 800V 1

.30

. .CR101

. . .

072 817..

RELAY, end 24VAC DPOT 1

.31 057 357

.. BUSHING, snap-in nyl .937 lOx 1.l2Smtg hole 2

.

32 +145 948.. BRACKET, mtg control box 1

.

33 Fig 9-6.. PANEL, front w/components 1

.

34 045 852.. CLIP, component .687dia mtg adh back 1

.35

...PC3

. . . .

138 060..

CIRCUIT CARD, relay control I

.36 PLG92,94 . .

131 052..


113746. . . . TERMINAL, female lskt24-18 wire 16

.

37 Fig 9-7..

CONTROL PANEL 1

120 304. . BLANK, snap-in nyl .25Omtg hole 5

119 951. . BLANK, snap-in nyt .437mtg hole 6

107 983. . BLANK, snap-in nyl .500mtg hole 1

024 103. . BLANK, snap-in nyl .75Omtg hole 1

000 527. .

BLANK, snap-in nyl .875mtg hole 4

OM-1584 Page 42

Table 9-1. Drive Roll And Wire Guide Kits

Wire Size

Wire,~~.auiue

V-GROOVE U-GROOVE V-KNURLED U-COGGED

Fraction Metric

Drive

Roll

Kit*

Drive~ ~

�

Drive

Roil

Kite

Drive~ ,,riO�

Drive

Roil

Klt*

DriveD ~~�

Drive

Roll

KIr

Drive

~

.023-.025 in. 0.6mm 132 740 140 915 087 130

.030 in. 0.8 mm 132 740 140916 053 695

.035in. 0.9mm 132740 140917 053700 140927 072000 140943 132958

.045in. 1.1 mm 132739 140918 053697 140928 053701 140944 132957 140961 083489

.052 in. 1.3 mm 132739 140919 053698 140929 053702 140945 132956 140962 083490

1/l6in. (.062 in.) 1.6 mm 132757 140920 053699 140930 053706 140946 132955 140963 053708

.068-.072in. 1.8mm 132757 140947 132959

5/641n.(.079in.) 2.0mm 132757 140931 053704 140948 132960 140964 053710

3/32 in. (.094 in.) 2.4mm 132738 140932 053703 140949 132961 140965 053709

7/64 in. (.110 in.) 2.8 mm 132738 140933 053705 140950 132962 140966 053711

1/Sin. (.125 in.) 3.2mm 138012 140934 053707 140951 132963 140967 053712

*Each kit includes 2 wire guides and 4 drive rolls. S.0549

CM-i 584 Page 43

C�) F~ 0)0 C~1

o ~- c~ c~) ~~. 1~ !~ ~

C,

a

F-

(0

c~1

(~1

C.)C�

In.

EQ(I)(I)

4

E00

0)

C)

U-

/

C�)

OM-1 584 Page 44

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


Quantity

Model

12 I 16

Item

No.

Part

No. Description

Figure 9-4. Boom Assembly (Fig 9-1 Item 16)

1 010313.. PIN, cotter hair .072x1.437 4

..

4

2 010 910. . WASHER, flat sti SAE .375 8

..8

3 139 590. . PULLEY, V sgl grv 8.875d1a x 8.000P x .375 bore 2

. .

2

4 079 667. .

PIPE, plstc .500 x 133.750 2

4 080 812. . PIPE, plstc .500 x 181 .750 2

5 079 632. . BOLT, U stl .250-20 x .875 wide x 1.375 deep 8

. .10

6 079 665.. GUIDE, wire

.2

6 080811.. GUIDE, wire 2

7 079 664.. GUIDE, wire inlet

. . .2.. 2

8 139 633. .

LINER, monocoil 3/32-1/8 wire x 15.687. . .

2. .

2

9 139832.. BOOM, dual. . .

1

9 139833.. BOOM, dual 1

..10 073 742

.. PIN, clevis .750 OD x 2.156 Ig 1..

1

11 073 741. .

CLEVIS, .812 yoke 6.062 Ig .750-l6thd 1. .

1

..

12 079 029.. NUT, sti hex full fnsh .750-16 2

. .

2

...13 075 462

.. SHAFT, boom counterbalance 1..

1

...14 602 250

..WASHER, flat sti SAE .750 2

..2

..15 079 020

..NUT, sti hex elastic stop .750-16 1

..

1

..16 149 858

.. SPRING, cprsn 3.75000 x .625 wire x 36.000 1.

...16 080 723

..SPRING, cprsn 3.750 OD x .687 wire x 33.750 1

..

17 150258..

RETAINER,washer 1..

1

...18 024 605

..BEARING, ball thr sgl row .750 x 1 .625 x .625 1

..

1

..

19 075 101.. NUT, sti hex special .750-16 x 1.250 1

..

1

...20 079 030

..WASHER, lock sti ext tooth .750 1

..

1

..21

....+139 831

..BASE, swivel boom (consisting of) 1

..

1

080 157. . . . FITTING, grease 1/8NPT 1

. .

1

...22 142 804

.. LABEL, Swingarc caution heavy spring 1..

1

...23 134 464

.. LABEL, warning general precautionary 1..

1

...24 602 246

.. WASHER, flat stl std .500 1..

1

...25 047 224

..KNOB, T-bar .500-13 I

..

1

...26 073 666

..BOLT, mach sti hexhd .750-16 x 2.750 1

..

1

...27 057357

..BUSHING, snap-in nyl .937 ID x 1.l25mtg hole 2

..

2

...28 139 818

..GUARD, motor protector 1

..

1

OM-1 584 Page 45

46

20

SeeTable9-1

For

DriveRoll&

WireGuideKits 28

SC-146271

11

10

7

2

14

1

15 16

7

6

I

I

~

I

�

_%

32

40

29

Figure9-5.

WireDrive

Assembly

Description Quantity

Figure 9-5. Wire Drive Assembly (Fig 9-1 Item 27)

Item

No.

PartNo.

..

1. . . .

132 742. . KNOB, spring shaft .375 ID x .625 ID 1

..2

. . . .133 739

. . WASHER, flat teflon .375 ID x .625 OD x .O62thk.

1

..3

. . . .132 747.. CARRIER, shaft 1

..4

. . . .078 671

. . PIN, spring CS .093 x .500 1

..5

. . . .132 824

.. SHAFT, spring 1

..6

. .. .145 635

. .SHIM, al .562 00 x .390 ID x .O2Othk (RH only) 2

..7

. . . .132 746.. BUSHING, spring 2

..8

. . . .133 603

. . SPRING, cprsn .72400 x .082 wire x 1.125 2

..9

. .. .132 823

. .RETAINER, spring 2

..10

. . . .137 248

. .SPRING, indicator 1

..

11. .. .

604 772. .

WASHER, flat stl SAE No. 8 1

..

12... .

602 200. . WASHER, lock stl split No. 8 1

..13

. . . .602 082

. .SCREW, mach stl rdh 8-32 x .500 1

..

14. . . .

133 493. .

RING, retaining ext .250 shaft x .O25thk 2

..15

. .. .133 350

. .PIN, hinge 1

..16.... 139346.. HINGE,cover 1

..17

. .. .602 008

. . SCREW, cap stl sch .250-20 x 1.000 2

..18

. . . .

141 044.. PIN, rotation pressure arm 2

..19

. . . .132 750

. .ARM, pressure 2

..20...

.133494.. HOLDER, guide 2

..21.... 133604.. CAP,guide 2

..22

. . . .145 072.. SCREW, cap sti sch .250-20 x .375 2

..

23. . . .

602 009.. SCREW, cap sti sch .250-20 x 1.250 4

..24

. .. .145 641

.. SCREW, retaining arm pressure 2

..25

. . . .

140 048. . WASHER, drive roll 4

..26

. . . .133 393.. CARRIER, drive roll quick release 4

..27

. . . .140 771

. . SCREW, shld stl sch .250-20 x .312 x .800 shld 4

..28.

.. .132 982

. .NUT, drive roll 4

..29

. . . .

139 347. .

COVER, drive roll 1

..

30. . . .

133 530. . DRIVE, pinion 1

..31

... .133 308

. .RING, retaining ext .375 shaft x .O25thk 1

..32

. . . .133 417

. . KEY, stl .125/.126 x .375 1

..33

. . . .601 965

. .SCREW, cap sti hexhd .375-16 x 1.000 1

..34

. . . .602 243

. .WASHER, flat sti std .375 2

..35.

. . .602 213

. .WASHER, lock stl split .375 1

..36...

.601 872

. .NUT, sti hex full fnsh .375-16 1

..37

... .136 674

. .WASHER, flat fbr .265 ID x .750 OD x .O62thk 2

..38

. . . .602 241

. .WASHER, flat sti SAE .250 3

..39

. . . .602 004

. .SCREW, cap stl sch .250-20 x .750 1

..40

. .. .145 636

. .KNOB, clamp bus bar 2

..

41... .

145 640. .

WASHER, shldr nyl .500 OD x .266 ID x .375 dia shldr 2

..42

. . . .

136 665. .

BUS BAR, interconnecting (LH only) 1

..42

. . . .139 221

. .BUS BAR, interconnecting (RH only) 1

..43

. . . .121 271

. .SCREW, cap stl sch .250-20 x .500 2

..44

. . . .

132 748. .

BLOCK, gun 1

..45

. .. .138 193

. .FITTING, brs barbed M 3/l6tbg x .250-20 1

..46..

. .134 834

. .HOSE, SAE .18710 x .410 OD (order by ft) 2ft

..

47... .

136 673. .

PLUG, insulating .568 hex x .22Othk 2

..48

. . . .145 637

. . STUD, lock bus bar 2

136 701. .

WRENCH, hex .187 short 1


OM-1 584 Page 47

4

10

*See Option that Is applicable

Figure 9-6. Panel, Front w/ComponentS

SC143 227

*

* 3

r

12

11

*

-.

�

��

�

�

~ �

-� ��

* 8 76

OM-1 584 Page 48

FIgure 9-6. Panel, Front w/Components (Fig 9-3 Item 33)

1... R1,2 ....

073562

..2 139225..

136339

�138548

..5... RC8,9.... 048282

079534

134846..

134842..

..8 112061..

9.. LED1,2 ...

089768

�134 379

�138 532

..8 112061

9.LED71/81

..089768

PLG72...

131 054

113746

R72-74/R82-84 073 562

097 922

604 645

�134684

�138536

8 112061

9.LED71/81

..089768

PLG72...

131 054

113746

R76,77/86,87 .603 856

097922

604 645

10 097922

11 604645

12

POTENTIOMETER, C sltd sft l/T 2W 10K ohm

PANEL, front

Part Of Optional 138 544 Digital Meter wlrach Feedback

COVER, opening meter


RECEPTACLE w/SOCKETS, (consisting of)TERMINAL, female lskt 18-14 wire

SWITCH, tgl SPTT 15A 125VAC

NUT, brs hex .468-32

CLIP, LED mtgLED, 5053 1 .7V I 5MA red

DUAL SCHEDULE, RH (consisting of)DUAL SCHEDULE, LH (consisting of) .

CLIP, LED mtgLED, 5053 1 .7V 1 5MA red

HOUSING RECEPTACLE & SOCKETS, (consisting of)TERMINAL, female lskt 24-18 wire

POTENTIOMETER, C sitd sft l/T 2W 10K ohm

KNOB, pointerNUT, stl hex .375-32

DIGITAL DUAL SCHEDULE, RH (consisting of)DIGITAL DUAL SCHEDULE, LH (consisting of)CLIP, LED mtgLED, 5053 1 .7V 1 5MA red

HOUSING RECEPTACLE & SOCKETS, (consisting of)TERMINAL, female lskt 24-18 wire

POTENTIOMETER, WW sitd sft 10/T 2W 10K ohm

KNOB, pointerNUT, stl hex .375-32

KNOB, pointerNUT, sti hex .375-32

NAMEPLATE, (order by model and serial number)

.2

�OPTIONAL


Item Dia.

No. Mkgs.Part

No. Description Quantity

2

1

1

1

1

1

4

2

2

2

1

1

4

1

1

OM-t 584 Page 49

1 2

6

FIgure 9-7. Control Panel

SB.146 340

IT

8-

3

7

L

>

6

OM-1584 Page 50

Figure 9-7. Control Panel (Fig 9-3 Item 37)

SWITCH, tgl SPOT 6A I25VAC 2

OPTION INTERFACE, RH (consisting of) 1

OPTION INTERFACE, LH (consisting of) 1

CIRCUIT CARD, option interface 1

STAND-OFF, No. 6-32 x .750 Ig 4


TERMINAL,female lskt24-l8wire 6



HOUSING PLUG & SOCKETS, (consisting of).

1


HOUSING PLUG & PINS, (consisting of) 1

TERMINAL, male 1 pin 24-18 wire 10

HOUSING PLUG & SOCKETS, (LH only) (consisting of) 3

TERMINAL, female 1 skt 24-18 wire 3

HOUSING PLUG & PINS, (LH only) (consisting of) 1




BURNBACK CONTROL, RH (consisting of) 1

BURNBACK CONTROL, LH (consisting of) 1

STAND-OFF, No. 6-32 x 1.500 Ig 2

CIRCUIT CARD, burnback 1

KNOB, pointer 1

HOUSING PLUG & SOCKETS, (consisting of)TERMiNAL, female I skt 24-18 wire

HOUSING PLUG & SOCKETS, (consisting of)TERMINAL, male 1 pin 24-18 wire

HOUSING PLUG & SOCKETS, (consisting of)TERMINAL, female lskt24-18 wire 3



SPOT/BURNBACK PREFLOW/POSTFLOW, RH (consisting of) 1

SPOT/BURNBACK PREFLOW/POSTFLOW, LH (consisting of) 1

STAND-OFF, No. 6-32 x 1.500 Ig 2

CIRCUIT CARD, 4-in-i timer 1

KNOB, pointer 4

PLATE, control 1

PANEL, face I


TERMINAL, female lskt 24.18 wire 8




TERMINAL,female lskt24-l8wire 4


TERMINAL,female iskt24-l8wire 3



BLANK, snap-in nyl .25Omtg hole 1

PLATE, control 2

PANEL, face 2

� Part of Optional 138 542 SpotlBurnback, Preflow/Postflow RH

�Part of Optional 138 547 SpotlBurnback, Preflow/Postflow LH

� �OPTIONAL


Item Dia.

No. Mkgs.PartNo. Description Quantity

1.. . S31,32 ..

�121 893

�~133305

��138528

..2... PC7O....

133071

115443

PLG16,54,76.115093

113746

PLG78,88 . .115 094

113746

PLG79,89 ..115091

113746

PLG8O,90 . .135 531

114656

PLG84,86,97.

131 204

113746

PLG85...

131 203

114656

PLG98...

131 056

113746

�~i38 546

��138 540

..5... PC1O....

PLG1,21,31

PLG22,32

PLG9O

PLG91

126 689

146 857

093551

115 092

113 746

135 409

114 656

131 204

113 746

115 093

113 746

��138542

�~138 547

3

8

2

8

..5... PC3O....

..6

PLG1,21,31

PLG22,32

PLG35

PLG9O

PLG91

..8

126 689

132 595

093 551

141 983

133 344

115 092

113 746

135409

114 656

115 094

113 746

131 204

113 746

115 093

113 746

120 304

141 982

133 344

OM-1584 Page 51

.138544

�132611

C61 147853

PLG5 130203

113746

PC5O 132370

PC51,52 133515

PC6O 135460

PLG62 131 055

113746

PLG63 138045

081 378

PLG64 084198

081 378

PLG95 115092

113746

R3,4 603856

115443

098691

138044

119261

138548

PC4O 134538

PLG41,61....

115094

113746

PLG42,84,86,97 .131 204

113746

PLG43,44. . . .

084 198

081 378

PLG47,49,85 �..131 203

114656

R75,85 603 856

097 922

604 645

132131

138538

108008

134379

138532

134684

138536

133305

138528

138546

138540

138542

138 547

DIGITAL METER w/TACH FEEDBACK (consisting of) 1

OPTICAL ENCODER, disc 1

CAPACITOR 1



CIRCUIT CARD, tach converter (Fig 9-3 Item 3) 1

CIRCUIT CARD, digital tach 1

CIRCUIT CARD, meter kit 1




TERMINAL, female 1 skt 22-18 wire 2

HOUSING, term hdr 6 pin 1




POTENTIOMETER, WW sltd sft 10/T 2W 10K ohm 2

STAND-OFF, No. 6-32 x .750 lg 2

STAND-OFF, No. 6-32 x .500 Ig 4

BUSHING, strain relief .120/.150 ID x .500mtg hole 1

WASHER, flat nyl .140 ID x .312 OD x .O32thk 10

See Fig 9-3 & 9-6 for additional parts 1

DIGITAL VOLTAGE CONTROL, (consisting of) (Fig 9-7 Item 4) 1

CIRCUIT CARD, control voltage digital 1





HOUSING, term hdr 6 pin 2

TERMINAL, female lskt22-l8wire 6

HOUSING PLUG & PINS, (consisting of) 1


POTENTIOMETER, WW sltd sft bIT 2W 10K ohm 1

KNOB, pointer 2

NUT, sti hex .375-32 2

RUN-IN, control RH, (see Fig 9-1 & 9-3) 1

RUN-IN, control LH (see Fig 9-1 & 9-3) 1

REEL, wire 60 lb (see Fig 9-2) 1

DUAL SCHEDULE, RH (see Fig 9-6) 1

DUAL SCHEDULE, LH (See Fig 9-6) 1

DIGITAL DUAL SCHEDULE, RH (see Fig 9-6) 1

DIGITAL DUAL SCHEDULE, LH (see Fig 9-6) 1

OPTION INTERFACE, RH (see Fig 9-7) 1

OPTION INTER FACE, LH (see Fig 9-7) 1

BURNBACK CONTROL, RH (see Fig 9-7) 1

BURNBACK CONTROL, LH (see Fig 9-7) 1

SPOT/BURNBACK PREFLOW/POSTFLOW, RH (see Fig 9-7) 1

SPOT/BURNBACK PREFLOW/POSTFLOW, LH (see Fig 9-7) 1


Dia.

Mkgs.Part

No. Description

Optional Equipment

Quantity

OM-1 584 Page 52

OPTIONS AND ACCESSORIES

EXTENSION CORDS

Provides 14-pin, 24 VAC, contactor

and remote power source voltagecontrol.

Can be added to the standard 10 ft.

(3 m) feeder cord to extend feeder

farther from power source.

INTERCONNECTING CORD

10 ft. (3 m) (#143 284)Includes 4-pin Amp connector for

connecting to PSA-2 control and

Hubbell connectors on older-styleMILLER CV power sources.

EXTENSION CORD

25 ft. (7.6 m) (#047 813)Extends Interconnecting Cord

(#143 284).

MOUNTING EQUIPMENT

FOR BOOM

One of the following is required for

mounting the Swingarc Booms:

� Swingpak Base

� CBC Cart (for use with 12ff. (3.7m) model only)

� Pipe Post

SWINGPAK BASES

SWINGPAK-1 2

(#085 276)For 12 ft. (3.7 m) boom

SWINGPAK-1 6

(085 934)For 16 ft. (4.9 m) boom

Note: A pipe post with a base plate Is

required and must be ordered separately.

PIPE POSTS

The Swingpak base will

accommodate a power source,

SwingarcTM feeder system, MPG395B Grid, Radiator 1A or 2A water

coolant system, gas cylinder, and

the AFT-i 00 Flux Tank for

Submerged Arc Welding. The base

plate is solid to help better organizecomponents and cables. A locker

with three compartments offers a

convenient place to store helmets,

gloves, tools, etc. The entire unit

can be moved with a fork lift truck.

CBC CARTS

CBC-8 Cart

CBC-8HD Cart

For 12 ft. (3.7 m) boom onlyThe CBC Cart is designed to

provide mobility and a neat, orderlyarrangement of welding equipment.The CBC-8 is the standard model

with 8 in. (203 mm) diameter by 2

in. (51 mm) wide wheels. A CBC

8HD heavy-duty model is designedfor use on rough or uneven

surfaces and features 12 in. (305mm) diameter by 3 in. (76 mm) wide

wheels.

Both models will accept a power

source, 12 ft. (3.7 m) Swingarcfeeder system, and two gas

cylinders or the AFT-i 00 flux tank

for Submerged Arc Welding.

The 16 ft. (4.9 m) Swingarc feeder

system cannot be mounted on a

CBC Cart.

Note: To mount a 12 ft (3.7 m) Swlngarcfeeder system on a CBC-8 Cart, a 6 ft

(1.8 m) Pipe Post Is required (#079 215).

PIPE POSTS

For 12 ft. Boom (3.7 m)18 In. (457 mm) Base Plate

For 16 ft. (4.9 m) Boom24 In. (610 mm) Base Plate

4 ft. (1.2 m) no base

4 ft. (1.2 m) with base

6 ft. (1.8 m) no base

6 ft. (1.8 m) with base

(#075 390)

(#079 591)

(#079215)

(#079 214)*

(#075 078)

(#078 264)

(#079 217)

(#079 216)

A pipe post with a base plate is required and must be ordered separately.

10 ft. (3 m)25 ft. (7.6 m)50 ft. (15 m)75 ft. (23 m)

(#122 972)(#122 973)(#122 974)(#122 975)

(#086 327)(#105 675)

1/91


OPTIONS TO CONTROLS

(Refer to the OPTION

COMPATIBILITY matrix for

combinative options.)

Note: The Option Interface is requiredwhen ordering the Dual Schedule Control,

Digital Dual Schedule Control, Remote

Pendant Control, Run-In Control or the

Interconnecting Cord for the RCSP-45

controL

BURNBACK CONTROL

(#138 540 Factory) left side only

(#138 546 Factory) right side only(#138 541 Field) left or right side

A 0 (zero) to 0.25 second timer which

allows the welding wire to burnback at

the completion of the weld.

VOLTAGE CONTROL

(#133 425 Field only) right side

(#138 527 Field only) left side

Installs in front panel of feeder to allow

remote voltage control of Miller

electrically controlled CV or CC/CV

power sources having a 14-pinreceptacle.

4-IN-i OPTION

Includes: spot/burnback, preflow,postf low, and trigger hold control.

(#138 547 Factory) left side only(#138 542 Factory) right side only(#138 543 Field) left or right side

This control is mounted on an inside

panel and includes 0 (zero) to 5 second

gas preflow and postf low control, up to

5 seconds of spot weld time, and up to

0.25 seconds of burnbad~ control. A

trigger hold control is also included,which allows the operator to make

extended welds without having to hold

the gun trigger.

DIGITAL METER WITh MOTOR

TACHOMETER FEEDBACK

(#138 544 Factory) both sides

(#138 545 Field) both sides

Allows the wire feed speed to be

precisely preset (via a ten-turn

potentiometer) on a Digital Meter and

accurately maintained (regardless of

changes in arc or load condition)compensating for line variations up to

~10%. The meter will also monitor and

display arc voltage, and it will hold the

voltage reading for 15 seconds after

completbn of the weld. The meter utilizes

a back-lit LCD and is easy to read in

virtually any lighting condition.

Note: For presettable voltage capability,refer to th. optional Digital Voltage Control.

HIGH SPEED MOTOR

(#132 130 Factory only) right side

(#132 129 Factory only) left side

The High Speed Motor has a wire feed

speed range of 90 to 1400 inches per

minute (2.3 to 35.6 rn/mm.).

Note: The high speed motor Is not

recommended for wire sizes larger than

5/64 In. (2.0 mm) diameter.

Note: If a standard speed motor and highspeed motor are used In combination on

this model, the optional Digital Metercannot be used.

PSA-2 CONTROL

(#141 604)Required when using the wire feeder

with power sources having only 115

VAC available. The PSA control can be

conveniently mounted on the wire

feeder or positioned at the power

source. The control is equipped with a

14-pin receptacle for direct connection

of the wire feeder control cord. A short

cord with a 4-pin Amp plug is hard-wired

to the control and will accept the control

cord of an existing 115 VAC Swingarcfeeder installation. If a compatible

mating control cord is not available,order the inter-connecting cord and

extension cord for required length(listed below). The PSA control can

also be used with competitive power

sources requiring a contact closure for

contactor control.

Note: If using the PSA with old-styleDeltaweldfi 450 and 650 power sources

and remote voltage control at the feeder

Is required, optional 5-pin Remote VoltageControl Cord (#136 267) Is required.

INTERCONNECTiNG CORD

10 ft. (3 m) (#143 284)Includes 4-pin Amp connector for

connecting to PSA-2 control and

Hubbell connectors on older-styleMILLER CV power sources.

EXTENSION CORD

25 ft. (7.6 m) (#047 813)Extends Interconnecting Cord (#143284).

5-PIN REMOTE VOLTAGE CONTROL

CORD

(#136 267 Field only)This cord is connected inside the 60

Series feeder and provides a 5-pinAmphenol plug for connecting to

DeltaweIdfi 450 and 650 power

sources that have 5-pin remote control

receptacles. This cord is required whenone of the following options are

installed in the wire feeder: Remote

Voltage Control, Digital Voltage Control,Dual Schedule Control, Digital Dual

Schedule Control, or the Remote

Pendant Conrol.

Note: The PSA-2 control must also be used.

EXTENSION CORD

25 ft. (7.6 m) (#041 294)Used to extend 5-pin Remote VoltageControl Cord (#136 267).

WIRE REEL ASSEMBLY

(#108 008)For 60 lb. (27 kg) coil of wire.

POLARITY REVERSING ISOLATiON

CONTROL

(#041 894)A dual-function control designed for use

with the dual wire feeder or any-

application where electrical isolation

and/or polarity reversing capabilities are

required. For example, one wire of the

feeder can be electrically cold while

welding with the other wire. The wires

can also be run on opposite or the

same polarity (straight or reverse). Both

functions can be performed at the same

time.

DUAL SCHEDULE SWITCHES

(For use with dual schedule

controls)DSS-8

(#079 691 Field)For 10 ft. (3 m) gun

(#079 693)For 15 ft. (4.6 m) gun

A two-position trigger switch which

attaches to the gun handle and is used

in place of the standard trigger.

DSS-9

(#071 832 Field only)For 10 ft. (3 m) gun

(#071 833 Field only)For 15 ft. (4.6 m) gun

A two-position slide switch which

attaches to the gun handle and is used

to select the desired welding condition

when two programs are used togetherfor dual schedule purposes. The

standard gun trigger operates the power

supply contactor.

1/91


ADJUSTABLE SPOOL CARRIER

(#096 075 Field only)Designed for use with 6 ft. (1.8 m) pipepost only. Replaces the standard spoolassembly, allowing the spools or coils

of wire to be positioned lower for easier

loading and unloading. Not

recommended for use with Swingarc~feeder system mounted on CBC-8 cart.

LOCKING COVERS

(#134 989 Field only)

Secures the front panel controls to

assure that the pro-selected weldingconditions are not changed.

Note: Padlock not Ineluded.

EXTENSION CORDS

Provides 14-pin, 24 VAC, contactor and

remote power source voltage control.

10 ft. (3 m) (#122 972)25 ft. (7.6 m) (#122 973)50 ft. (15 m) (#122 974)75 ft. (23 m) (#122 975)

Can be added to the standard 10 ft. (3m) feeder cord to extend feeder farther

from power source.

WATER COOLANT SYSTEMS

For use with water-cooled guns.

(#042 492)Radiator 1A 115 VAC

(#042 494)Radiator 1A 115 VAC 100 Hz

(#042 493)Radiator 2A 230 VAC

(#042 495)WatermateTM 1A 115 VAC

(#042 496)Watermate~ 2A 230 VAC

(#042 288)Coolmate~ 4115 VAC

(#042 289)CoolmateTM 4230 VAC

Refer to Literature Index No. AW7.2 for

additional coolant system information.


(#138 548 Factory) bothsides

(#138 549 Field) both sides

The Digital Voltage Control (DVC)allows the arc voltage to be preciselypreset (via a ten-turn potentiometer) to

the nearest 1/10 volt on the digital meter

and accurately monitors and maintains

this voltage while welding. The DVC is

designed for use with Miller electricallycontrolled CV or CC/CV power source

having a 14-pin receptacle.

Note: When the Digital Voltage Control is

used with Miller Inverter-type powersources, the control functions as a

remote digital control, allowing the arc

voltage to be preset and displayed onthe feeder digital meter.

Note: To install and use the DVC, the

optional Digital Meter with Tach Feedback

Is required.

OPTION INTERFACE

(#133 305 Factory) right side

(#133 306 Field) right side

(#138 528 Factory) left side

(#138 529 Field) left side

The Option Interface is required when

installing the Dual Schedule Controls,Run-In Control, Remote Pendant

Control, or the Interconnecting Cord for

the RCSP-45 control.

Note: Only one Option Interface is

required for any combination of

compatible options requiring the Optioninterface. Refer to option matrix.

Note: if any options that requir. the Optioninterface are to be installed on both

sides of a dual model, the Optioninterface is required for both sides.

DIGITAL DUAL SCHEDULE

CONTROL




(#138537 Field) left side

Allows two separate welding conditions

(voltage and wire feed speed) to be

used on one wire. The parameters can

be accurately preset (via ten-turn

potentiometers) on the digital meter.

Note: The Digital Meter with Tach

Feedback, Digital Voltage Control, and

Option interface control are required to

install the Digital Dual Schedule Control.

Refer to the OPTIONAL CONTROLS AND

ACCESSORIES section for appropriatedual schedule switches.

DUAL SCHEDULE CONTROL

(#134379 Factory) right side

(#134380 Field) right side


(#138533 Field) left side

This is a non-digital dual schedule

control which includes three single-turn

potentiometers to allow two separate

welding conditions (voltage and wire

feed speed) to be used on one wire.

Note: if the Dual Schedule Control ii used

only on one side of the dual model), the

opposite side must have the optionalRemote Voltage Control Installed.

Note: The Option Interface is required to

install the Dual Schedule Control. Refer

to the OPTIONAL CONTROLS AND

ACCESSORIES section for appropriatedual schedule switches.

REMOTE PENDANT CONTROL

Includes 31 ft. (9.4 m) cord for

connection to wire feeder control.

(#133 304 Field only) right side

(#138 538 Field only) left side

Allows the voltage and wire feed speedto be adjusted remote from the main

feeder control. Also includes a two-

position switch to allow the operator to

select parameters set on the feeder

control or the pendant control. Three

single-turn potentiometers are included

� two installed in the pendant and one

for the feeder control.

Note: if the Remote Pendant Control Is

used only on one side of the dual model,the opposite side must have the optionalRemote Voltage Control, Dual Schedule

Control, or Digital Dual Schedule Control

Installed.

Note: The Option interface Is required to

Install the Remote Pendant Controi. Refer

to the OPTIONAL CONTROLS AND

ACCESSORIES sectIon for appropriatedual schedule switches.

RUN-IN CONTROL




(#138 531 Field) left side

An adjustable wire run-in start control

that allows the run-in wire feed speed to

be set higher or lower than the actual

welding speed. This control can also be

used as a touch start control by simplyturning the run-in control to 0 (zero).

Note: The Option Interface I. required to

install the Run-In ControL

t/9 I

iii Millerfi

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