OWN R™S

May 1981 FORM: OM-1536

OWNER�SMANUAL

1!I1,lI!rI!\ \~ fi, 7

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MILLER ELECTRIC MFG. CO.718 S. BOUNDS ST. P.O. Box 1079

APPLETON, WI 54912 USA

ADDITIONAL COPY PRICE 90 CENTS

NWSA CODE NO. 4579

PRINTED IN U.S.A.

Effective With Serial No. JE1500222

MODEL

AUTOMATIC 1 D

�L ~ �~.� ~o� �L~ �~�~� �t~�m�

LIMITED WARRANTYEFFECTIVE: JUNE 1. 1979

This warranty supersedes all previous MILLER warranties and is ex

clusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY-Subject to the terms and conditions As a matter of general policy only, Miller may honor claims

hereof, Miller Electric Mfg. Co. Appleton, Wisconsin warrants submitted by the original user within the foregoing periods.to its Distributor/Dealer that all new and unused Equipment

(� furnished by Miller is free from defect in workmanship and In the case of Miller�s breach of warranty or any other dutymaterial as of the time and place of delivery by Miller. No war- with respect to the quality of any goods, the exclusive remedies

ranty is made by Miller with respect to engines, trade ac- therefore shall be, at Miller�s option 11) repair or (2) replacementcessories or other items manufactured by others. Such or, where authorized in writing by Miller in appropriate cases, (3)

engines, trade accessories and other items are sold subject to the reasonable cost of repair or replacement at an authorized

the warranties of their respective manufacturers, if any .

All Miller service station or (4) payment of or credit for the purchaseengines are warranted by their manufacturer for one year from price (less reasonable depreciation based upon actual use) upon

date of original purchase, return of the goods at Customer�s risk and expense. Upon receipt

of notice of apparent defect or failure, Miller shall instruct the clai-

Except as specified below, Miller�s warranty does not apply mant on the warranty claim procedures to be followed.

to components having normal useful life of less than one lii

year, such as spot welder tips, relay and contactor points, ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

MILLERMATIC parts that come in contact with the welding ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA- ?wire including nozzles and nozzle insulators where failure does TION AS TO PERFORMANCE, AND ANY REMEDY FOR

not result from defect in workmanship or material. BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,

MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,Miller shall be required to honor warranty claims on war- CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING

ranted Equipment in the event of failure resulting from a defect ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF

within the following periods from the date of delivery of Equip- FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO

ment to the original user: ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX

CLUDED AND DISCLAIMED BY MILLER.

1. Arc welders, power sources and components . .

1 year

2. Original main power rectifiers 3 years EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN

(labor - 1 year only) WRITING, MILLER PRODUCTS ARE INTENDED FOR

3. All welding guns and feeder/guns 90 days ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL

4. All other Millermatic Feeders 1 year USERS AND FOR OPERATION BY PERSONS TRAINED AND

5. Replacement or repair parts, exclusive of labor.

60 days EXPERIENCED IN THE USE AND MAINTENANCE OFd 6. Batteries 6 months WELDING EQUIPMENT AND NOT FOR CONSUMERS OR

CONSUMER USE. MILLER� WARRANTIES DO NOT EXTEND

provided that Miller is notified in writing within thirty (30) days TO, AND NO RESELLER IS AUTHORIZED TO EXTEND

of the date of such failure. MILLER�S WARRANTIES TO, ANY CONSUMER.

j�

TABLE OF CONTENTS

Section No. Page No.

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

1 - 1. Introduction 1

1 - 2. General Precautions 1

1 -3. Arc Welding 3

1 - 4. Standards Booklet Index 4

SECTION 2 - INTRODUCTION

2 - 1. General Information And Safety 5

2 - 2. Receiving-Handling 5

2 - 3. Description 5

SECTION 3 - INSTALLATION

3-1. Location 6

3 - 2. Shielding Gas Connections 6

3 -3. Water Connections 6

3 - 4. Remote Start And Stop Connections 7

3 - 5. Normally-Open And Normally-Closed Contacts Available For Control

Of Weld Fixtures 7

3 - 6. Weld Control Interconnections 8

SECTION 4 - FUNCTION OF CONTROLS

4 - 1. Power Switch 10

4 - 2. Retract-Advance Switch And Inch Switch 10

4 - 3. Purge Push-Button Switch 10

4 - 4. Start Push-Button Switch 10

4 - 5. Stop Push-Button Switch 11

4 - 6. Error Reset Button 11

4-7. PressTo Set Buttons 11

4 - 8. Digital Voltmeter 11

4 - 9. Digital Inches Per Minute Meter 11

4-10. Weld Voltage Control 11

4-11. WeldWireSpeedControl 11

4-12. Run-In Wire Speed Control 11

4-13. Run-In Voltage Control 11

4-14. RunlnlimeControl 12

4-15. Crater & Inch Wire Speed Control 12

4-16. Crater Voltage Control 12

4-17. Pre-FIow Time Control 12

4-18. Spot-Continuous Switch 12

4-19. SpotlimeControl 12

4-20. Crater Time Control 12

4-21. BurnbackControl 12

4-22. Post-Flow Time Control 12

4-23. Overload Protection 12

SECTION 5 - SEQUENCE OF OPERATION

5 - 1. Gas Metal-Arc Welding & Flux Cored Arc Welding - Continuous 13

5-2. Gas Metal-Arc Welding&Flux Cored Arc Welding-Spot 13

5 - 3. Shutting Down 13

SECTION 6 - MAINTENANCE & TROUBLESHOOTING

6-1. Inspection And Upkeep 13

6-2. General 14

6 - 3. Troubleshooting Chart 14

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

1-1. INTRODUCTION

We learn by experience. Learning safety through personal

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

wasteful, and unwise. Let the experience of others teach you.

Safe practices developed from experience in the use of weld

ing and cutting are described in this manual. Research, devel

opment. and field experience have evolved reliable equipmentand safe installation, operation, and servicing practices. Acci

dents occur when equipment is improperly used or main

tained. The reason for the safe practices may not always be

given. Some are based on common sense, others may requiretechnical volumes to explain. It is wiser so follow the rules.

Read and understand these safe practices before attemptingso install, operate, or service the equipment. Comply with

shese procedures es applicable to she particular equipmentused and their instruction manuals, for personal safety and

for she safety of others.

Failure so observe these safe practices may cause serious in

jury or death. When safety becomes a habit, the equipmentcan be used wish confidence.

These safe practices are divided into two Sections: 1 -

General Precautions, common to arc welding and cutting; and

2 - Arc Welding (and Cutting((only(.

Reference standards: Published Standards on safety are also

available for additional and more complete procedures than

those given in this manual. They are listed in she Standards

Index in this manual. ANSI Z49,1 is the most complete.

The National Electrical Code, Occupational Safety and

Health Administration, local industrial codes, and local in

spection requirements also provide a basis for equipment in

stallation, use, and service.

GENERAL PRECAUTIONS

Burn Prevention

Wear protective clothing - leather (or esbestos( gaunslesgloves, has, and high safesy-soe shoes. Button shirt collar and

pocket flaps, and wear cuffless trousers to avoid entry of

sparks and slag.

Wear helmet wish safety goggles or glasses with side shields

underneath, appropriate filter lenses or plates (prorected byclear cover glass(. This is a MUST for welding or cutting, (and

chipping( to protect the eyes from radiant energy and flyingmesal. Replace cover glass when broken, pitted, or spattered.See 1-3A.2.

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

Hot metal such as electrode stubs and workpieces should

never be handled without gloves.

Medical first aid end eye treatment. First aid facilities and a

qualified first aid person should be available for each shift

unless medical facilities are close by for immediate treatment

of flash burns of she eyes and skin burns.

Ear plugs should be worn when working on overhead or in a

confined space. A hard hat should be worn when others work

overhead.

Flammable hair preparations should not be used by persons

inrending to weld or cut.

B. Toxic Fume Prevention

Adequate ventilation. Severe discomfort, illness ordeath can

result from fumes, vapors, heat or oxygen enrichment or

depletion that welding (or cutsing( may produce. Prevent

them with adequate ventilation aa described in ANSI Stan

dard Z49.1 listed 1 in Standards index, NEVER ventilate

with oxygen.

Lead -. cadmium ., zinc ., mercury ., and beryllium - bearingand similar materials, when welded (or cus( may produce

harmful concentrations of toxic fumes. Adequate local

exhaust ventilation must be used, or each person in the area

as well as the operator must wear an air-supplied respirator.

For beryllium, both must be used.

Metals coated with or containing materials that emit toxic

fumes should not be heated unless coating is removed from

the work surface, the area is well ventilated, or she operator

wears an air-supplied respirator.

Work in a confined space only while it is being ventilated

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

Gas leaks in a confined space should be avoided. Leaked gas

in large quantities can change oxygen concentration danger

ously. Do not bring gas cylinders into a confined space.

Leaving confined space, shut OFF gas supply as source to

prevent possible accumulation of gases in the space if down

stream valves have been accidently opened or left open.

Check to be sure that the space is safe before re-entering it.

Vapors from chlorinated solvenrs can be decomposed by theheat of the arc (or flame( to form PHOSGENE, a highly toxic

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

violet (radiant( energy of the arc can also decompose tn

chloroeshylene and perchioroethylene vapors to form phosgene. DO NOT WELD or cut where solvent vapors can be

drawn into the welding or cutting atmosphere or where the

radiant energy can penetrate to atmospheres containing even

minute amounts of tnichioroethylene or perchloroethylene.

C. Fire and Explosion Prevention

Causes of fire and explosion are: combustibles reached by the

arc, flame, flying sparks, hot slag or heated material; misuse

of compressed gases and cylinders; and short circuits.

BE AWARE THAT flying sparks or falling slag can pass

through cracks, along pipes, through windows or doors, and

through wall or floor openings, out of sight of the goggledoperator. Sparks and slag can fly 35 feet.

To prevent fires and explosion:

Keep equipment clean and operable, free of oil, grease, and

(in electrical parts( of metallic particles that can cause short

circuits.

If combustibles are in area, do NOT weld or cut. Move the

work if practicable, to an area free of combustibles. Avoid

paint spray rooms, dip tanks, storage areas, ventilators. If the

work cannot be moved, move combustibles as least 35 lees

away out of reach of sparks and heat; or protect againstignition with suitable and snug-fitting, fire-resistant covers or

shields.

Walls touching combustibles on opposite sides sh ould not be

welded on (or cut(. Walls, ceilings, and floor near work

should be protected by heat-resistant covers or shields.

Fire watcher must be standing by with suitable fire ex

tinguishing equipment during and for some time after weld

ing or cutting if:

a. appreciable combustibles (including building construc

sion( are within 35 feet

b. appreciable combustibles are further than 35 feet but can

be ignited by sparksc. openings (concealed or visible( in floors or walls within 35

feet may expose combustibles to sparksd. combustibles adjacent to walls, ceilings, roofs, or motel

partitions can be ignited by radiant or conducted heat.

Hot work permit should be obtained before operation to

ensure supervisor�s approval that adequate precautions havebeen taken.

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

An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must never bewelded on or cut, unless container has first been cleaned as

described in AWS Standard A6.O, listed 3 in Standards index.

1-2.

A.

OM-1536 Page 1

This includes: a thorough steam or caustic cleaning (or a

solvent or water washing, depending on the combustible�s

solubility) followed by purging and inerting with nitrogen or

carbon dioxide, and using protective equipment at recom

mended in A6,0. Waterfilling just below working level may

substitute for inerting.

A container with unknown contents should be cleaned (see

paragraph above). Do NOT depend on sense of smell or sightto determine if it is safe to weld or cut

Hollow castings or containers must be vented before weldingor cutting, They can explode,

Explosive atmospheres. Never weld or cut where the air maycontain flammable dust, gas, or liquid vapors (such as gaso

line)-

D. Compressed Gas Equipment

Standard precautions. Comply with precautions in this

manual, and those detailed in CGA Standard P-i, PRECAUTIONS FOR SAFE HANDLING OF COMPRESSED GASES

IN CYLINDERS, listed 6 in Standards index.

1. Pressure Regulators

Regulator relief valve is designed to protect only the regulator from overpressure; it is not intended to protect any

downstream equipment. Provide such protection with one or

more relief devices.

Never connect a regulator to a cylinder containing gas other

than that for which the regulator was designed.

Remove faulty regulator from service immediately for repair(first close cylinder valve). The following symptoms indicate

a faulty regulator:

Leaks - if gas leaks externally,Excessive Creep - if delivery pressure continues to rise with

downstream valve closed.

Faulty Gauge - if gauge pointer does not move off stop pinwhen pressurized, nor returns to stop pin after pressure

release.

Repair. Do NOT attempt repair. Send faulty regulators for

repair to manufacturer�s designated repair center, where

special techniques and tools are used by trained personnel.

2. Cylinders

Cylinders must be handled carefully to prevent leaks and

damage to their walls, valves, or safety devices:

Avoid electrical circuit contact with cylinders including third

rails, electrical wires, or welding circuits. They can produceshort circuit arcs that may lead to a serious accident. (Seei-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 gasmarked on them; do not rely on color to identify gas con

tent. Notify supplier if unmarked. NEVER DEFACE or alter

name, number, or other markings on a cylinder. It is illegaland hazardous.

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

Prohibited use. Never use a cylinder or its contents for other

than its intended use, NEVER as a support or roller.

Locate or secure cylinders so they cannot be knocked over.

Passageways and work areas. Keep cylinders clear of areas

where they may be struck.

Transporting cylinders. With a crane, use a secure supportsuch as a platform or cradle. Do NOT lift cylinders off the

ground by their valves or caps, or by chains, slings, or mag

nets.

Do NOT expose cylinders to excessive heat, sparks, slag, and

flame, etc. that may cause rupture. Do not allow contents to

exceed 130°F. Cool with water spray where such exposureexists.

Protect cylinders particularly valves from bumps, falls, fallingobjects, and weather. Replace caps securely when movingcylinders.

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

cylinder valve that can not be opened by hand. Notify your

supplier.

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

Never refill any cylinder.

Cylinder fittings should never be modified or exchanged.

3. Hose

Prohibited use. Never use hose other than that designed for

the specified gas. A general hose identification rule is: red for

fuel gas, green for oxygen, and black for inert gases.

Use ferrules or clamps designed for the hose (not ordinarywire or other substitute) as a binding so connect hoses to

fittings.

No copper tubing splices. Use only standard brass fittings to

splice hose.

Avoid long runs to prevent kinks and abuse. Suspend hose off

ground to keep it from being run over, stepped on, or other

wise damaged.

Coil excess hose to prevent kinks and tangles.

Protect hose from damage by sham edges, and by sparks,slag, and open flame.

Examine hose regularly for leaks, wear, and loose connec

tions, Immerse pressured hose in water; bubbles indicate

leaks.

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

4. Proper Connections

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

from people and sources of ignition. Wipe with a clean lint-

less cloth.

Match regulator to cylinder. Before connecting, check that

the regulator label and cylinder marking agree, and that the

regulator inlet and cylinder outlet match. NEVER CON

NECT a regulator designed for a particular gas or gases to a

cylinder containing any other gas.

Tighten connections, When assembling threaded connections,clean and smooth seats where necessary. Tighten. If connec

tion leaks, disassemble, clean, and retighten using properly

fitting wrench.

Adapters. Use a CGA adapter (available from your supplier)between cylinder and regulator, if one is required. Use two

wrenches to tighten adapter marked RIGHT and LEFT

HAND threads.

Regulator outlet (or hose) connections may be identified byright hand threads for oxygen and left hand threads (with

grooved hex on nut or shank) for fuel gas.

5. Pressurizing Steps;

Drain regulator of residual gas through suitable vent before

opening cylinder (or manifold valve) by turning adjustingscrew in (clockwise). Draining prevents excessive compressionheat at high pressure seat by allowing seat to open on pressur

ization. Leave adjusting screw engaged slightly on single-stageregulators.

Stand to side of regulator while opening cylinder valve.

Open cylinder valve slowly so that regulator pressure in

creases slowly. When gauge is pressurized )gauge reaches regulator maximum) leave cylinder valve in following position:For oxygen, and inert gases, open fully so seal stem againstpossible leak. For fuel gas, open to less than one turn to

permit quick emergency shutoff.

Page 2

Use pressure charts (available from your supplier) for safe

and efficient, recommended pressure sestings on regulators.

Check for leaks on first pressurization and regularly there

after. Brush with soap solution (capful of Ivory Liquid or

equivalent per gallon of water). Bubbles indicate leak. Clean

off soapy water after test; dried soap is combustible.

E. User Responsibilities

Remove leaky or defective equipment from service immed

iately for repair. See User Responsibility statement in 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 cut

ting operation; rope may burn.

1-3. ARC WELDING

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

Welding, properly done, is a safe process, but a careless opera

tor invites trouble. The equipment carries high currents at

significant voltages. The arc is very bright and hot. Sparks fly,fumes rise, ultraviolet and infrared energy radiates, weld

ments are hot, and compressed gases may be used. The wise

operator avoids unnecessary risks and protects himself and

others from accidents. Precautions are described here and in

standards referenced in index.

A. Burn Protection

Comply with precautions in 1-2.

The welding arc is intense and visibly bright Its radiation can

damage eyes, penetrate lightweight clothing, reflect from

light-colored surfaces, and burn the skin and eyes. Skin burns

resemble acute sunburn, those from gas-shielded arcs are

more severe and painful. DON�T GET BURNED; COMPLY

WITH PRECAUTIONS.

1. Protective Clothing

Wear long-sleeve clothing (particularly for gas-shielded arc) in

addition to gloves, hat, and shoes )1-2A). As necessary, use

additional protective clothing such as leather jacket or

sleeves, flame-proof apron, and fire-resistant leggings. Avoid

outergarments of untreated cotton.

Bare skin protection. Wear dark, substantial clothing. Button

collar to protect chest and neck and button pockets to pre

vent entry of sparks.

2. Eye and Head Protection

Protect eyes from exposure to arc. NEVER look at an elec

tric arc without protection.

Welding helmet or shield containing a filter plate shade no.

12 or denser must be used when welding. Place over face

before striking arc.

Protect filter plate with a clear cover plate.

Cracked or broken helmet or shield should NOT be worn;

radiation can pass through to cause burns.

Cracked, broken, or loose filter plates must be replaced IM

MEDIATELY. Replace clear cover plate when broken, pitted,or spattered.

Flash goggles with side shields MUST be worn under the

helmet to give some protection to the eyes should she helmet

not be lowered over the face before an arc is struck. Lookingat an arc momentarily with unprotected eyes (particularly a

high intensity gas-shielded arc) can cause a retinal burn that

may leave a permanent dark area in the field of vision.

3. Protection of Nearby Personnel

Enclosed welding area. For production welding, a separate

room or enclosed bay is best. In open areas, surround the

operation with low-reflective, non-combustible screens or

panels. Allow for free air circulation, particularly at floor

level.

Viewing the weld. Provide face shields for all persons who

will be looking direÆtly at the weld.

Others working in area. See that all persons are wearing flash

goggles.

Before starting to weld, make sure that screen flaps or bay

doors are closed.

B. Toxic Fume Prevention

Comply with precautions in 1-2B.

Generator engine exhaust must be vented to the outside air.

Carbon monoxide can kill.

C. Fire and Explosion Prevention

Comply with precautions in 1-2C.

Equipment�s rated capacity. Do not overload arc weldingequipment. It may overheat cables and cause a fire.

Loose cable connections may overheat or flash and cause a

fire.

Never strike an arc on a cylinder or other pressure vessel. It

creates a brittle area that can cause a violent rupture or lead

to such a rupture later under rough handling.

D. Compressed Gas Equipment

Comply with precautions in 1-2D.

E. Shock Prevention

Exposed hot conductors or other bare metal in the weldingcircuit, or in ungrounded, electrically-HOT equipment can

fatally shock a person whose body becomes a conductor. DO

NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet sur

face when welding, without suitable protection.

To protect against shock:

Keep body and clothing dry, Never work in damp area with

out adequate insulation against electrical shock. Stay on a

dry duckboard, or rubber met when dampness or sweat can

not be avoided. Sweat, sea water, or moisture between bodyand an electrically HOT part - or grounded metal - reduces

the body surface electrical resistance, enabling dangerous and

possibly lethal currents to flow through the body.

1, Grounding the Equipment

When installing, connect the frames of each unit such as

welding power source, control, work table, and watçr circula

tor to the building ground. Conductors must be adequate to

carry ground currents safely. Equipment made electricallyHOT by stray current may shock, possibly fatally. Do NOT

GROUND to electrical conduit, or to a pipe carrying ANY

gas or a flammable liquid such as oil or fuel.

Three-phase connection, Check phase requirement of equipment before installing. If only 3-phase power is available,connect single-phase equipment to only two wires of the

3-phase line. Do NOT connect the equipment ground lead to

the third (live) wire, or the equipment will become electri

cally HOT - a dangerous condition that can shock, possiblyfatally.

Before welding, check ground for continuity. Be sure conduc

tors are touching bare metal of equipment frames at connec

tions.

If a line cord with a ground lead is provided with the equipment for connection to a switchbox, connect the ground lead

to the grounded switchbox. If a three-prong plug is added for

connection to a grounded mating receptacle, the ground lead

must be connected to the ground prong only. If the line cord

comes with a three-prong plug, connect to a grounded matingreceptacle. Never remove the ground prong from a plug, or

use a plug with a broken off ground prong.

Trademark of Proctor & Gamble.

OM-1536 Page 3

2. Electrode Holders

Fully insulated electrode holders should be used. Do NOTuse holders with protruding screws.

3. Connectors

Fully insulated lock-type connectors should be used to joinwelding cable lengths.

4. Cables

Frequently inspect cables for wear, cracks and damage.IMMEDIATELY REPLACE those with excessively worn or

damaged insulation to avoid possibly - lethal shock frombared cable. Cables with damaged areas may be taped to giveresistance equivalent to original cable.

Keep cable dry, free of oil and grease, and protected fromhot metal and sparks.

5. Terminals And Other Exposed Parts

Terminals and other exposed parts of electrical units shouldhave insulating covers secured before operation.

6. Electrode Wire

Electrode wire becomes electrically HOT when the powerswitch of gas metal-arc welding equipment is ON and weldinggun trigger is pressed. Keep hands and body clear of wire andother HOT parts.

7. Safety Devices

Safety devices such as interlocks and circuit breakers shouldnot be disconnected or shunted Out.

Before installation, inspection, or service, of equipment, shutOFF all power and remove line fuses (or lock or red-tagswitches) to prevent accidental turning ON of power. Disconnect all cables from welding power source, and pull all 115volts line-cord pIu~.

Do not open power Circuit or change polarity while welding.If, in an emergency, it must be disconnected, guard againstshock burns, or flash from switch arcing.

Leaving equipment unattended. Always shut OFF and dis

connect all power to equipment.

Power disconnect switch must be available near the weldingpower 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 WeldingSociety, 2501 NW 7th St.. Miami, Fla. 33125.

2. ANSI Standard Z87.1, SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards

institute, 1430 Broadway, New York, N.Y. 10018.

3. American Welding Society Standard A6.0, WELDINGAND CUTTING CONTAINERS WHICH HAVE HELD

COMBUSTIBLES, obtainable same as item 1.

4. NFPA Standard 51. OXYGEN-FUEL GAS SYSTEMS

FOR WELDING AND CUTTING. obtainable from the

National Fire Protection Association, 470 AtlantIc

Avenue, Boston, Mass. 02210.

5. NFPA Standard 51B, CUTTING AND WELDING PRO

CESSES, obtainable same as item 4.

6. CGA Pamphlet P-i. SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtain~,Ie from the

Compressed Gas Association, 500 Fifth Avenue, New

York, N. Y. 10036.

7. OSHA Standard 29 CFR, Part 1910, Subpart 0, WELDING, CUTTING AND BRAZING.

8. Code for Safety in Welding and Cutting, CSA Standard

W117.2.

Page 4

SECTION 2 - INTRODUCTION

Dimensions

WeightHeight Width Depth

Weld Control17-1/2 in.

(445 mm)

13-7/8 in.

(352 mm)

8 in.~

(203 mm)

32-1/2 lbs.

(14.7 kg)

Gas Control4-1/8 in.

(105 mm)

5-1/8 in.

(130 mm)

10-1/2 in.

(267 mm)

4-1/2 lbs.

(2.0 kg)

Wire Feed

Speed Range50 in. (1.3 m) to 780 in. (19.8 m) per minute

*Add 1 in. (25.4 mm) for front panel controls.

Figure 2-1. Specifications

2 - 1. GENERAL INFORMATION AND SAFETY

A. General

IMPORTANTA third signal word,______________,

highlights instruc

tions which need special emphasis to obtain the most

efficient operation of this equipment.

WARNING CAUTION

Information presented in this manual and on various

labels, tags, and plates provided on the unit pertains to

equipment design, installation, operation, maintenance,and troubleshooting which should be read, understood,and followed for the safe and effective use of this equipment.

B. Safety

The installation, operation, maintenance, and

troubleshooting of arc welding equipment requirespractices and procedures which ensure personal safetyand the safety of others. Therefore, this equipment is to

be installed, operated, and maintained only by qualifiedpersons in accordance with this manual and all ap

plicable codes such as, but not limited to, those listed at

the end of Section 1 - Safety Rules For Operation Of

Arc Welding Power Source.

Safety instructions specifically pertaining to this unit ap

pear throughout this manual highlighted by the signalwords

___________

and___________

which identifydifferent levels of hazard.

~:statements include installation, operating,and maintenance procedures or practices which if not

carefully followed could result in serious personal injuryor loss of life.

~UIl.1~I statements include installation, operating,and maintenance procedures or practices which if not

carefully followed could result in minor personal injuryor damage to this equipment.

2 - 2. RECEIVING-HANDLING - Prior to installingthis equipment, clean all packing material from around

the unit and carefully inspect for any damage that mayhave occurred during shipment. Any claims for loss or

damage that may have occurred in transit must be filed

by the purchaser with the carrier. A copy of the bill of

lading and freight bill will be furnished by the carrier Ofl

request if occasion to file claim arises.

When requesting information concerning this equipment, it is essential that Model Description and Serial

(or Style) Number of the equipment be supplied.

2 - 3. DESCRIPTION - This weld control providesdigital meter display of voltage and wire speed and

allows preselection and meter display of welding condi

tions before operation begins as well as continuous

display during the weld cycle. This unit is also designedto automatically cycle preprogrammed welding events

and provide a constant wire feed speed and arc voltageregardless of conditions. This unit is to be used with the

Deltaweld series of power sources.

The standard weld control has provisions to select the

PREFLOW TIME, RUN-IN WIRE SPEED, WELD

VOLTAGE, WELD WIRE SPEED, CRATER & INCH

WIRE SPEED, CRATER VOLTAGE, CRATER TIME,SPOT TIME, BURNBACK TIME, and POSTFLOW

TIME, with RUN-IN VOLTAGE and RUN IN TIME con

trols optional. Normally-open and normally-closed contacts are provided on each time control to interface with

other equipment (for example, starting and stopping a

welding fixture).

For information on the wire drive and spool supportassemblies, see Owner�s Manual 1538.

OM-1 536 Page 5

SECTION 3 - INSTALLATION

4-1/8 in. 5/16 in. (7.9 mm)

(105 mm)~LI ameter 2 Holes

li

~ 9-7/8 in.

- (251 mm)

10-1/2 in.__________

(267 mm)

3 - 1. LOCATION (Figure 3-1) - The service life and

efficiency of this unit and associated components will

be reduced when they are subjected to high levels of

dust, dirt, moisture, corrosive vapors, and extreme

heat.

The location should allow room to open the front paneland to remove wrapper(s) for installation, inspection,maintenance, and repair functions.

Provisions have been made for mounting the gas con

trol assembly on the bottom of the weld control. The

gas control assembly may also be mounted anywhere in

line with the welding gun thereby avoiding routing the

weld cables and gas hoses back to the weld control.

Lead lengths must be considered when locating all com

ponents of the weld control.

Mounting holes are provided in the gas assembly and

weld control. Figure 3-1 gives overall dimensions and

mounting hole layout.

3 -2. SHIELDING GAS CONNECTIONS (Figure3-5) - Connect a hose (not supplied) of proper lengthand construction from shielding gas supply (regulatorflowmeter) to fitting on the IN panel of gas control

assembly. The gas fitting is a 5/8-18 connector with

right-hand threads. The gas flow must be accuratelycontrolled by a regulator and flowmeter at the source.

Connect supplied gas hose from remaining fitting on

gas control assembly to barbed fitting on wire drive

housing.

3 - 3. WATER CONNECTIONS (Optional)

C MJTIION_________

OVERHEATING Gas Metal-Arc

Welding (GMAW) gun can damage gun.� If using a water-cooled gun and recirculating

coolant system, make connections from the

coolant system directly to the gun hoses. Do not

use water connections on the gas control

assembly. Check system periodically for proper

coolant flow.

When a recirculating coolant system is not employed,and use of the provided solenoid valve is desired, make

TA-080 485 water connections at gas control assembly. The water

fittings are 5/8-18 connectors with left-hand threads.

Connect water hose from supply to fitting on IN pane)of gas control assembly. Connect another hose bet

ween remaining fitting on gas control and gun IN fitting.Connect and route a hose from gun OUT fitting to a

proper drain. Check system periodically for proper

coolant flow.

7-3/4 in.

(197 mm)

(130 mm)

Coolant will flow as soon as the POWER switch on the

weld control is placed in the ON position. If coolant flow

is desired only in conjunction with shielding gas flow,

1~A-O8O 429proceed as follows: Locate the lead connected from pin8 of receptacle RC9 to terminal B on terminal strip 2T.

Figure 3-1. Overall Dimensions And Mounting Disconnect this lead from terminal B on 2T, and recon

Hole Layout nect it to terminal C on terminal strip iT.

Page6

~j~V1PORTANT For information on the wire drive and

spool support assemblies, see Owner�s Manual 1538.

5. Connect remaining lead to terminal A on terminal

strip 2T.

3 -4. REMOTE START AND STOP CONNEC

TIONS

6. Place the SPOT-CONTINUOUS switch in the

SPOT position.

I~tVARNlNG: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.� Shut down the weld control and disconnect input

power (115 vac) before making any terminal stripconnections.

For remote control of starting and stopping, connec

tions must be made to terminal strips iT and 2T in the

weld control. Loosen screw from door on upper panelof the weld control and open door. Terminal strips 1 T

and 2T are located on the right side of the control.

A. Momentary-Contact Push-Button Switch

1. Route cord from switch(es) through strain relief

clamp on right side of weld control (see Figure3-4).

2. Remove jumper link between terminals G and F

on terminal strip iT.

3. Connect the two leads from the normally-openstart switch to terminals F and H on 1 T.

4. Connect the two leads from the normally-closed

stop switch to terminals G and F on iT.

B. Maintained-Contact (Relay) Switch

1. Route cord from relay through strain relief clampon right side of weld control (see Figure 3-4).

2. Remove jumper link between terminals F and E


7. Closing the switch will start weld cycle and unit

will weld for the time set on the SPOT TIME con

trol. The setting of the pre-flow and post-flowtimers determines how long weld current is not

present and thereby determines the skip time.

The unit will automatically recycle through the

weld cycle until the switch is opened.

After all connections are secured, close door on upper

panel of weld control and tighten screw.

( To Terminal A_________

On 2T

To Weld J To Terminal E

Control On iT

I To Terminal F

is,. OniT

Figure 3-2. Skip Welding Switch Connections

3 - 5. NORMALLY-OPEN AND NORMALLY-

CLOSED CONTACTS AVAILABLE FOR CONTROL

OF WELD FIXTURES (Figure 3-3) - A set of

normally-open and normally-closed contacts are provided to work in conjunction with each weld cycle timingcircuit. These contacts may be used to determine fix

ture movement in conjunction with the weld cycle. For

example: If the operator wants the fixture to start mov

ing at arc initiation and stop when the STOP push but

ton is depressed, the normally-open contacts of CR51

(at receptacle RC4, terminals F and H) would be used to

control fixture movement.

3. Connect the normally-open maintained contact

of the relay to terminals F and H on 1 T.

4. Closing relay contact will start unit and openingrelay contact will stop unit.

C. Skip Welding (Figure 3-2)

1. Route a 3-conductor cord from a single-pole,double-throw switch through strain relief clampon right side of weld control (see Figure 3-4).

2. Remove jumper link between terminals F and E


3. The switch commons of the single-pole, double-

throw switch should be tied together to one lead

of the 3-conductor cord. Connect this lead of the

3-conductor cord to terminal F on terminal strip1 T.

4. Connect one of the two remaining leads to ter

minal E on terminal strip iT.

WARNING: ELECTRIC SHOCK can kill.

� Do not touch live electrical parts.� Shut down the weld control and disconnect input

power (115 vac) before making any internal con

nections.

Connections can be made to the 3/16� male friction

connectors on receptacles RC4 and RC1O located

behind the timing circuit card assembly in the weld con

trol. To gain access to these receptacles, the timing cir

cuit card assembly may be removed as follows:

1. Loosen screw from door on upper panel of the

weld control and open door.

2. Remove three screws securing timer panel.

3. Gently pull timer panel part way out.

4. Remove plugs PLG1 and PLG2 from the printedcircuit card assembly.

5. Remove timer panel.

Single-Pole,Double-Throw Switch

TA-044 484-A

OM-1 536 Page 7

I I

CR54 F- � � � �

U

a

UI

a

C

U

a

*The dotted line condition indicates the time during the weld

cycle that the control relay is deenergized. The solid line condi

tion Indicates the time during the weld cycle that the control

relay is energized.

Route leads from the receptacles through the strain

relief clamp provided on the side of the weld control.

After connections are made to the receptacles, reverse

the steps to install the timer panel.

3 - 6. WELD CONTROL INTERCONNECTIONS

(Figure 3-4)

WARNING ELECTRIC SHOCK can kill.

Do not touch five electrical parts.� Shut down we/ding power source and be sure it

cannot be accidentally energized before makinginterconnections.

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

the following connections.

A. Voltage Sensing Connections

Connect the 4-pin plug from the voltage sensing cord to

weld control receptacle A (see Figure 3-4). Connect re

maining ends as follows: Connect lead with clamp at

tached to workpiece. Connect lead with ring terminal

attached to weld cable terminal on wire drive housing(see Owner�s Manual 1538 for location of weld cable

terminal).

B. Voltage Control Connections

Connect the 4-pin plug from the voltage control cord to

weld control receptacle B (see Figure 3-4). Connect re

maining end to VOLTAGE CONTROL receptacle on

welding power source. Place VOLTAGE CONTROL

switch on welding power source in the REMOTE posI

C. Motor Control Connections

Connect the 9-pin plug from the motor control cord to

weld control receptacle C (see Figure 3-4). Connect re

maining end to plug from drive motor.

D. Gas Control Connections

Connect the 14-pin plug from the gas control cord to

weld control receptacle D (see Figure 3-4). Connect re

maining end to receptacle on gas control assembly (see

Figure 3-5).

J~i~ J~R5~~ J~R54 CR~, ~ ~R5s4

4~ ~D ~ F kR L ~ CC

-i I--

-~

Fixture (Example explained in Section 3-5.)

CR56*

CRS5

~� �

I!

II

ii

�I

CR50

CR51

CR52

I,

�I

I,

��H--it-----H-~

-

I,

�I

Run In Speed

Pre-Flow Time~ 0.5 Sec.

Weld Time Spot Time

0- InfinityOr

0-2.5 Sec.

Crater Time

0-2.5 Sec.

START

Arc

Initiation

Burnback Time

0-025

STOP Time

Figure 3-3. Weld Control Cycle

TB-080 432

tion.

Page8

1. Select and prepare proper size weld cables ac

cording to welding power source Owner�s

Manual.

2. Remove cover from gas control assembly.

3. Connect a weld cable to the positive (+) weld

output terminal on welding power source.

IMPORTANT Instructions are given for DC Reverse

Polarity connections. For DC Straight Polarity connec

tions, connect a weld cable to the negative (-1 weld out

put terminal on welding power source, route cable

through gas control~, and connect to weld cable terminal

on wire drive housing. Connect another weld cable from

positive (+1 weld output terminal on welding power

source to the work.

E. 115 VAC And Contactor Control Connec

tions

Connect the 4-pin plug from the 115 volts ac and con

tactor control cord to weld control receptacle E (see

Figure 3-4). Connect remaining ends to welding power

source as follows: Connect 2-prong plug to CONTAC

TOR CONTROL receptacle, and connect 3-prong plugto 115 VOLTS AC twistlock receptacle. Place CON

TACTOR CONTROL switch on welding power source in

the REMOTE position.

F. Weld Output Connections (Figure 3-5)

~~1:1~II~�Ief ELECTRIC SHOCK can kill.

o Do not touch five electrical parts.o Shut down the welding power source and be sure

it cannot be accidentally energized before makingweld output connections.

4. Route positive (+) weld cable through grommeton IN panel of gas assembly, through reed

switch bracket, and out grommet on oppositeend (see Figure 3-5).

5. Route and connect positive (+) weld cable to

weld cable terminal on wire drive housing (see

Owner�s Manual 1538).

6. Connect a weld cable from the negative (-) weld

output terminal on welding power source to the

work.

7. Reinstall cover onto gas control assembly.

14-Pin; Gas

Control Assembly-D

Figure 3-4. Interconnection Points On Weld Con

trol

TA-071) 483

Figure 3-5. Gas Control Assembly

OM-1536 Page 9

SECTION 4 - FUNCTION OF CONTROLS

Inch Circuit

PurgeButton

TC-070 484

4 - 1. POWER SWITCH (Figure 4-1) - Placing the

POWER switch on the weld control in the ON positionwill apply 115 volts ac to the unit and thereby place it in

an operational condition, permitting the preprogrammed welding cycle to start when the START button is

depressed, or gas to flow when the PURGE button is

depressed, or welding wire to feed if the INCH switch is

depressed. The meters will illuminate showing the

selected WELD VOLTAGE and WELD WIRE SPEED.

Placing the POWER switch in the OFF position wilI shut

the weld control and associated components down.

This switch must be in the ON position to preprogram

the desired weld cycle.

4 -2. RETRACT-ADVANCE SWITCH AND INCH

SWITCH (Figure 4-1) - With the RETRACT-

ADVANCE switch in the RETRACT position, the

welding wire will retract into the gun at the speed set bythe CRATER & INCH WIRE SPEED control only while

the INCH switch is activated.

With the RETRACT-ADVANCE switch in the AD

VANCE position, the welding wire will advance from the

gun at the speed set by the CRATER & INCH WIRE

SPEED control only while the INCH switch is activated.

The INCH switch is a normally-open, momentary-

contact, toggle switch. Activating the switch will

energize the drive motor without energizing the weldingpower source contactor or the gas control circuitry.

4 - 3. PURGE PUSH-BUTTON SWITCH (Figure4-1) - The PURGE push-button switch is a normally-open, momentary-contact switch. Depressing the pushbutton will energize the gas solenoid and thereby purgethe shielding gas line to the gun.

4 - 4. START PUSH-BUTTON SWITCH (Figures4-1 & 3-3) - Depressing the START push-buttonswitch will start the preprogrammed weld cycle. See

Figure 3-3 for weld cycle events. The weld cycle will

continue until the STOP push-button switch is depressed or the SPOT TIME control times out.

Figure 4-1. Front Panel Controls

Page 10

4 - 5. STOP PUSH-BUTTON SWITCH (Figures 4-1

& 3-3) - Depressing the STOP push-button switch will

initiate the preprogrammed crater fill, burnback, and

post-flow time. See Figure 3-3 for weld cycle events.

4 -6. ERROR RESET BUTTON (Figure 4-1) - The

Voltage Reset button, labeled ERROR RESET, is provided to reset the Voltmeter if the preset voltage is beyondthe limitations of the welding power source. If the load

voltage remains lower or higher than the preset voltagefor more than 1 .5 seconds, the Voltmeter display will

begin to flash. Once the display begins to flash, it will

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

tained by the welding power source or welding opera

tions cease. Depress the ERROR RESET button to stop

the Voltmeter display from flashing.

During normal equipment operation, the condition

which would cause the display to flash would be a

preset voltage which is out of the range of the welding

power source (at a particular line voltage and load cur

rent) or improper connection of voltage sensing leads.

Ensure that leads are properly connected (see Section

3-6A) and that connections are clean and tight. Read

just the preset voltage before resuming operation.

4-7. PRESS TO SET BUTTONS (Figure4-1) - Two

white push-button switches are provided for presettingweld cycle conditions. Each button governs the two

controls directly below it. Pressing (and holding) the

RUN-IN button allows presetting of the RUN-IN WIRE

SPEED and optional RUN-IN VOLTAGE (if applicable).

Pressing the CRATER & INCH button allows presettingof the CRATER VOLTAGE and CRATER & INCH WIRE

SPEED. When either of these buttons is pressed, the

values selected on the applicable controls will appear on

the meter displays. The POWER switch must be in the

ON position for these buttons to be functional. When

the buttons are released, the meters will display the

selected WELD VOLTAGE and WELD WIRE SPEED.

(See Sections 4-8 and 4-9 for additional meter displayinformation.)

4 - 8. DIGITAL VOLTMETER (Figure 4-1) - This

meter displays voltage to the nearest tenth of a volt.

The POWER switch must be in the ON position for the

meter to function. With the POWER switch in the ON

position, but before the START button is depressed,this meter will display WELD voltage. In all cases,

regardless of options, WELD voltage as selected by the

WELD VOLTAGE control is displayed during preflow,

weld, burnback, and postflow times. Crater voltage, as

selected by the CRATER VOLTAGE control, is

displayed during CRATER TIME. If the optional RUN-INVOLTAGE and RUN IN TIME controls are present, Run-

In Voltage, as selected by the RUN-IN VOLTAGE con

trol, is displayed during Run-In and until the RUN IN

TIME control times out after arc initiation.

II ~ I ~s. fit� I~ If voltmeter display is erratic duringrun in and crater time, no malfunction is present. The

meter does not have sufficient time to change and

stabilize the display. Regardless, the unit will still pro

vide the preset values if within its capability.

IMPORTANT

4 - 9. DIGITAL INCHES PER MINUTE METER

(Figure 4-1) - This meter displays wire speed in inches

per minute. The POWER switch must be in the ON position for the meter to function. With the POWER switch

in the ON position, but before the START button is

depressed, this meter will display WELD wire speed. In

all cases, regardless of options, wire speed as selected

by the WELD WIRE SPEED control is displayed during

preflow, weld, burnback, and postflow time. Crater

speed, as selected by the CRATER & INCH SPEED

CONTROL, is displayed during CRATER TIME. Run-In

speed, as selected by the RUN-IN SPEED control, is

displayed during Run In time (after preflow until arc in

itiation). If the optional RUN-IN VOLTAGE and RUN IN

TIME controls are present, Run-In speed, as selected bythe RUN-IN SPEED control, is displayed during Run-In

time (after preflow until arc initiation). If the optionalRUN-IN VOLTAGE and RUN IN TIME controls are pre

sent, Run-In speed, as selected by the RUN-IN SPEED

control, is displayed during Run-In and until the RUN IN

TIME control times out after arc initiation.

______________

If meter display is erratic during run in

and crater time, no maffunction is present. The meter

does not have sufficient time to change and stabilize the

display. Regardless, the unit will still provide the preset

values if within its capability.

4-10. WELD VOLTAGE CONTROL (Figuire4-1) - The WELD VOLTAGE control provides a means

of selecting the desired voltage during the Weld portionof the cycle (see Section 4-8).

Rotating this control clockwise increases the WELD

voltage. This control is a 10-turn potentiometer.

4-11. WELD WIRE SPEED CONTROL (Figure4-1) - The WELD WIRE SPEED control provides a

means of selecting the rate at which welding wire will

feed into the weld during the Weld portion of the cycle(see Section 4-9).

Rotating this control clockwise increases the WELD

wire feed speed. This control is a 10-turn potentiometer.

4-12. RUN-IN WIRE SPEED CONTROL (Figure4-1) - The RUN-IN WIRE SPEED control provides a

means of selecting the rate at which welding wire will

feed after preflow and prior to arc initiation (or until the

optional RUN IN TIME control times out after arc initia

tion, if applicable). After arc initiation (or after optionalRUN IN TIME control times out, if applicable), the wire

feed speed is governed by the WELD WIRE SPEED con

trol. The selected Run-In Wire Speed will be displayedby the INCHES PER MINUTE meter during the Run-In

period.

Rotating this control clockwise increases the wire feed

speed during the Run-In portion of the cycle. This con-

trolls a 10-turn potentiometer.

4-13. RUN-IN VOLTAGE CONTROL

(Optional) - The Optional RUN-IN VOLTAGE control,located directly above the RUN-IN WIRE SPEED con-

OM-1536 Page 11

trol, provides a means of selecting the voltage duringthe Run-In portion of the welding cycle (see Section

4-12 for explanation). The selected voltage will be

displayed by the voltmeter during the Run-In period.

Rotating this control clockwise increases the Run-In

voltage. This control is a 10-turn potentiometer and is

provided as an optional package which includes the

RUN IN TIME control.

4-14. RUN IN TIME CONTROL (Optional) - The

Optional RUN IN TIME control, located to the right of

the CRATER WIRE SPEED and CRATER VOLTAGE

controls, provides a means of selecting the length of

time for the Run-In portion of the cycle after arc initia

tion. This adjustable 0 to 2.5 seconds control beginstiming out the selected value upon arc initiation. When

the selected time has elapsed, the unit goes to the weld

portion of the cycle.

4-15. CRATER & INCH WIRE SPEED CONTROL

(Figure 4-1) - The CRATER & INCH WIRE SPEED

control provides a means of selecting the rate at which

wire will feed into the weld during the Crater Time and

the rate at which wire will advance or retract when the

INCH switch is depressed. The selected speed will be

displayed by the INCHES PER MINUTE meter duringthe Crater Time period.

Rotating this control clockwise increases the wire feed

speed during the Crater Time portion of the cycle. This

control is a 10-turn potentiometer.

4-16. CRATER VOLTAGE CONTROL (Figure4-1) - The CRATER VOLTAGE control provides a

means of selecting the voltage during the Crater Time

portion of the welding cycle. The selected voltage will

be displayed on the voltmeter during the Crater Time

period.

Rotating this control clockwise increases the voltageduring the Crater Time portion of the cycle. This control

is a 10-turn potentiometer.

4-17. PRE-FLOW TIME CONTROL (Figure4-1) - An adjustable 0 to 5 seconds PRE-FLOW TIME

control is provided for selecting the period of time

shielding gas flows before arc initiation. The PRE

FLOW TIME control starts to time when the START

switch is depressed.

Rotating this control clockwise increases the pre-flowtime. The scale surrounding the PRE-FLOW TIME con

trol is calibrated in seconds to aid in the selection of a

pre-flow time period suited to the individual weldingoperation.

4-18. SPOT-CONTINUOUS SWITCH (Figure4-1) - The SPOT-CONTINUOUS switch provides the

means to select either normal weld cycle or a timed

weld cycle. Placing the SPOT-CONTINUOUS switch in

the SPOT position will provide a timed weld as deter

mined by the SPOT TIME control. Placing the SPOT-

CONTINUOUS switch in the CONTINUOUS positionwill cause the weld control to operate normally.

4-19. SPOT TIME CONTROL (Figure 4-1) - An ad

justable 0 to 2.5 seconds SPOT TIME control is provided for selecting the time welding wire will feed into the

weld at the speed selected by the WELD WIRE SPEED

control. The SPOT TIME control starts to time out at

arc initiation.

Rotating this control clockwise increases the spot time.

The scale surrounding the. SPOT TIME control is

calibrated in seconds to aid in the selection of a spottime suited to the individual welding operation.

4-20. CRATER TIME CO~JTROL (Figure 4-1) - An

adjustable 0 to 2.5 seconds CRATER TIME control is

provided for selecting the time welding wire will feed in

to the weld at the rate set by the CRATER & INCH

WIRE SPEED control. The CRATER TIME control starts

to time out when the STOP switch is depressed or when

the SPOT TIME control times out.

Rotating this control clockwise increases the Crater

Time. The scale surrounding the CRATER TIME control

is calibrated in seconds to aid in the selection of a Crater

Time period suited to the individual welding operation.

4-21. BURNBACK CONTROL (Figure 4-1) - An ad

justable 0 to 0.25 seconds BURNBACK control is provided for selecting the time the welding wire will remain

electrically energized after the drive motor stops. The

BURNBACK control starts to time out after the

CRATER TIME control has timed out.

Rotating this control clockwise increases the burnback

time. The scale surrounding the BURNBACK control is

calibrated in seconds. By adjusting this control proper

ly, the welding wire will neither freeze in the weld puddle nor in the contact tube of the gun. If the weldingwire freezes to the work, increase the burnback time. If

the welding wire burns back into the contact tube,decrease the burnback time.

4-22. POST-FLOW TIME CONTROL (Figure4-1) - An adjustable 0-5 seconds POST-FLOW TIME

control is provided for selecting the time shielding gaswill flow after the BURNBACK control has timed out.

Rotating this control clockwise increases the post-flowtime. The scale surrounding the POST-FLOW TIME

control is calibrated in seconds to aid in the selection of

a post-flow time period suited to the individual weldingoperation.

4-23. OVERLOAD PROTECTION (Figure4-1) - The weld control is protected from damage due

to an internal short or excessive overload, by fuse Fl.

Fuse Fl is located on the front panel. If fuse Fl should

open, the weld control would completely shut down.

The drive motor is protected from damage due to

overload by circuit breaker CB1.Circuit breaker CB1 is

located on the front panel of the weld control. If circuit

breaker CB1 should open, the weld control would com

pletely shut down. The reset button would have to be

manually depressed to reset the circuit breaker.

Page 12

SECTION 5 - SEQUENCE OF OPERATION

ELECTRIC SHOCK can kill; MOVING

PARTS can cause serious injury.o Do not touch live electrical parts.o Keep clear of moving parts.The welding wire and all metal parts in contact with it

are energized while welding.ARC RAYS, SPARKS, AND HOT SURFACES can

burn eyes and skin; NOISE can damage hearing.' Wear correct eye, ear, and body protection.FUMES AND GASES can seriously harm your

health.

o Use enough ventilation to keep fumes and gasesfrom the breathing zone.

See Section 1 - Safety Rules For Operation Of Arc

Welding Power Source for basic welding safety infor

mation.

S - 1. GAS METAL-ARC WELDING (GMAW) &

FLUX CORED ARC WELDING (FCAW) - CON

TO~UOUS

1. Mount and position all components.

2. Make all connections as instructed in Section 3.


CONTINUOUS position (see Section 4-18).

4. Turn on shielding gas at the source.

5. Energize the welding power source.

6. Place the weld control POWER switch in the ON

position (see Section 4-1).

7. Program the desired weld cycle by setting the

controls as instructed in Section 4.

8. Purge the gas line by depressing the PURGE but

ton for one minute (see Section 4-3).

9. Depress the weld control START button (see

Section 4-4).

10. To terminate the weld cycle, depress the weld

control STOP button (see Section 4-5).

5 - 2. GAS METAL-ARC WELDING (GMAW) &

FLUX CORED ARC WELDING (FCAW) - SPOT

1. Mount and position all components.

2. Make all connections as instructed in Section :3.


SPOT position (see Section 4-18).

4. Rotate the SPOT TIME control to the desired


5. Turn on shielding gas at the source.

6. Energize the welding power source.

7. Place the weld control POWER switch in the ON


8. Program the desired weld cycle by setting~ the

controls as instructed in Section 4.

9. Purge the gas line by depressing the PURGE but

ton for one minute (see Section 4-3).

10. Depress the weld control START button (see

Section 4-4).

11. The weld cycle will automatically terminate when

the SPOT TIME control times out.

5 - 3. SHUTFING DOWN

1. Place the weld control POWER switch in the OFF

position.

2. Turn off all associated equipment.

3. Turn off the shielding gas at the source.

~ HIGH CONCENTRATION OF

SHIELDING GAS can harm health or kill.

S Shut off gas supply when not in use.

SECTION 6 - MAINTENANCE & TROUBLESHOOTING

~jj~J1~c~ ELECTRIC SHOCK can kill.

S Do not touch live electrical parts.S Disconnect unit from input power and shut down

welding power source before internally inspectingor servicing.

Troubleshooting of internal parts to be performed only

by qualified persons.

6 - 1. INSPECTION AND UPKEEP

_______________

Periodically inspect the labels on thisunit for legibility. All labels must be maintained in a

c/early readable state and replaced when necessary.See the Parts List for part number of labels.

IMPORTANT

OM-1536 Page 13

Usage and shop conditions will determine the frequencyand type of maintenance. Inspect equipment as follows:

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

give particular attention to frayed and cracked in

sulation and areas where it enters equipment.

2. Remove grease and grime from components;moisture from electrical parts and cable.

6 � 2. GENERAL - It is assumed that proper installa

tion has been made, according to Section 3 of this

manual, and that the unit has been functioning properlyuntil this trouble developed.

IMPORTANT:_____

Be sure that all connections on side of

weld control and at components are correct and secure

according to Section 3, and that all controls and swit

ches are in proper positions according to Section 4,

before proceeding with troubleshooting.

6 - 3. TROUBLESHOOTING CHART - The follow

ing chart is designed to diagnose and provide remedies

for some of the troubles that may develop in this unit.

Use this chart in conjunction with the circuit diagramwhile performing troubleshooting procedures. If the

trouble is not remedied after performing these pro

cedures, the nearest Factory Authorized Service Sta

tion should be contacted. In all cases of equipmentmalfunction, the manufacturer�s recommendations

should be strictly followed.

TROUBLE PROBABLE CAUSE REMEDY

Depressing START button

will not start weld cycle,Electrode wire is not

energized and shielding gas

does not flow.

POWER switch Si in

wrong position or defec

tive.

Place POWER switch Si to ON position.

Replace defective POWER switch Si.

Circuit breaker CBi tripped. Manually reset circuit breaker CBi by depressingbutton on front panel labeled PRESS TO RESET.

115 volts ac input power

plug is not secure in recep-

tacle on welding power

source.

Insert plug fully into ii 5 VAC twistlock receptacleon welding power source and rotate plugclockwise (see Section 3-6E).

115 volts ac input fuse Fi

open.

Locate and replace fuse Fl on front panel.*

Wire feeds, shielding gas

flows, but electrode wire is

not energized.

Contactor Control plug is

not secure in receptacle on

welding power source.

Insert plug fully into CONTACTOR CONTROL

receptacle on welding power source and rotate

plug clockwise (see Section 3-6E).

Defect in welding power

source.

See troubleshooting section in welding power

source instruction manual.

Erratic voltmeter display. Incorrect or loose voltagesensing connections.

Check connections and be sure they are correct

and secure (see Section 3-6A).

Voltage control plug is not

secure in receptacle on

welding power source.

Connect voltage control plug securely to

VOLTAGE CONTROL receptacle on weldingpower source (see Section 3-6B).

*If it becomes necessary to replace any fuse in this unit, ensure that a fuse of the proper size, type, and rating is

used.

Page 14

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______-~_____

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~

CircuitDiagramNo.

D~83075

~j>72

>~S3lS3

~L

~________

22

ft

I112

aFigure6-1.

CircuitDiagram

May1981 FORM: OM-1536

PARTSLIST

Effective With Serial No. JB500222

MODEL

Automatic 1 D

//

--

-~

mN

C

CI-

I-

N

0)

CDI-

NI

COI-

inI-,

�

--

ein

inin

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Nto

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�C0CD

0

C

0

C.;)40

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ii.

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coin emNN NN

CoCo

mCo

70)� Co

OM-1536 Page 1

Item Dia.

No. Mkgs.

Part

No. Description Quantity

Figure A 070 184 Control Box

1 Fl *012 655 FUSE, miniature-glassi0amp250 volts 1

2 071 230 BEZEL/FILTER 2

3 071 119 DOOR, cabinet 1

4 070 370 METER,volt-digital(FigAl Pg4) 2

5 PLG6,15 081 379 HOUSING, connector- edge 12 pin receptacle 2

6 026 837 INSULATOR, terminal - nylon 1

7 CB1 011 991 CIRCUIT BREAKER, 1 pole 1.5 amp 250 volts 1

8 51 011 611 SWITCH,toggleDPDTl5ampl25volts 1

9 S2,3 011 043 SWITCH, toggle DPDT6amp l25voIts 2

10 PB1 011 232 SWITCH, push button SPDT 1

11 C2,3 028 291 CAPACITOR,ceramic0.1 uf500voltsdc 2

12 073 487 NUT, speed No. 2 1

13 +071 000 CABINET,control 1

14

15�

047

024

497

376

LABEL, general precautionaryBLANK, snap-in 5/8 mounting hole

1

2

16 057084 BUSHING,snap 1

17 010 193 TUBING,3/8ODxl8gawaIIxl/4 6

18 079 683 HEAT SINK, resistor 1

19 HEATSINK 1

20 R2 030 941 RESISTOR,WWfixedl00watt5ohm 1

21 056 170 SHIELD, resistor 1

22 TUBING,0.275IDx0.O48waIlxl 2

23 t049 989 CABLE, volt - sensing (consisting of) 1

24 073 686.PLUG,4socketMS-3106A-14S-2S 1

25 039 828. CLAMP, cable 1

26 600 848. WIRE, stranded 12 ga (order by ft) 35 ft

27 604 109 .WIRE,strandedl6ga(orderbyft) 19 ft

28 600 750. TERMINAL, ring tongue 1/2 stud 1

29 601 226. INSULATOR, vinyl - clamp 1

30 601 228. CLAMP, universal 1

31 t047 001 CORD, interconnecting - control (consisting of) 1

32 047 544. PLUG,4socketMS-3l06A-14-2SX 1

33 039 828. CLAMP, cable 1

34 600341 .CORD,No.16 3/c(orderbyft) lOft

35 039 685. CLAMP, cable 1

36 039 273. PLUG, 5 pin MS-3106A-16S-8P 1

37 t071 006 CORD, motor (consisting of) 1

38 PLG7 048

079

306

535.RECEPTACLE & PINS (consisting of)

. . TERMINAL, male

1

6

39 079 706. CLAMP, cable 2

40 073 139. CORD, No. 16 6/c (order byft) 10 ft

41 PLG8(F) 048

079

380

534

.HOUSING PLUG & SOCKETS (consisting of)

. . TERMINAL, female

1

6

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

42 t071 005 CORD, interconnecting (consisting of) 1

43 PLG9 047

079

636

535.

HOUSING PLUG & PINS (consisting of)

. . TERMINAL, male

1

14

44 079 739. CLAMP, cable 2

45 073 139. CORD, No.16 6/c (order byft) lift

46 PLG16 048

079

598

534

.HOUSING PLUG & SOCKETS (consisting of)


1

16

47 t018 964 CORD, control - interconnecting (consisting of) 1

48 048

079

284

534.HOUSING PLUG & SOCKETS (consisting of)


1

4

49 079531 .CLAMP,cable i

OM-1536 Page 2

-

Description Quantity

Figure A 070 184 Control Box (Cont�d.)

50 604571 .CORD,No.18 4/c(orderbyft) lOft

51 039 687. CAP, twistlock - grounded 2P3W 1

52 049455 .CORD, No. 18 2/c(orderbyft) 2ft

53 039 635.CONNECTOR BODY, twistlock2P2W 1

54 010 610 CONNECTOR, clamp - cable 1/2 inch 1

55 070371 BLANK,snap-in 1

56 RC13 047 543 RECEPTACLE, 4 pin MS-3102A-14S-2PX 1

57 RC7,9 047 637 HOUSING RECEPTACLE & SOCKETS (consisting of) 2

079 534. TERMINAL, female 14

048 144 TERMINAL, male - plug keying (located in receptacle) 4

58 RC1 1 048 283 RECEPTACLE, w/pins (consisting of) 1

079 535. TERMINAL, male 4

59 RC12 076 624 RECEPTACLE, 4 pin MS-3102A-14S-2P 1

60 Figure A2 PANEL, w/components (Pg 6) 1

61 048464 TIMERASSEMBLY(FigA3Pgll) 1

62 R4-6,22,23 071 996 POTENTIOMETER, WW 10 turn2 watt 10K ohm 5

63 071 226 BARRIER, switch - end 2

64 PB4 070 530 SWITCH, w/button - red 1

65 071 225 BARRIER, switch - center 1

66 PB3 070 531 SWITCH,w/button-green 1

67 024 366 KNOB, pointer - line indicator 5

68 NAMEPLATE (order by model & serial number) 1

69 PB2,5,6 070 529 SWITCH, w/button - white 3

70 046 432 HOLDER, fuse - panel mounting (consisting of) 1

71 059 139. CAP, holder-fuse 1

72 010 853 FASTENER, screw No.2 1

010 855 RETAINER, screw No. 2 1

73 079 844 SPRING, hold down - relay 1

74 CR2 081 797 RELAY, enclosed 24 volts ac 4PDT 1

75 027 811 CONNECTOR, 14 pin 1

76 048 029 CLIP, retaining - socket relay 1

t056 462 HOSE ASSEMBLY, gas 10 ft (consisting of) 1

010 603. FITTING, hose - barbed nipple 1/4 TBG 1

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

056298 .HOSE,gas 1

*Recommended Spare Parts.

tThese items not included with control box.

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

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

Item Dia.

No. Mkgs.

Part

No.

Page 3

2

COMPONENTS TO BE

REPLACED BY QUALIFIED

PERSONNEL ONLY

TB-O1O 451

Figure Al - Meter, Volt - Digital


Item

No.

Dia. Part

Mkgs. No. Description Quantity

Figure Al 070 370 Meter, Volt-Digital (Fig A Pg 2 Item 4)

1 071 669 COVER, volt - meter digital 1

2 071 200 CIRCUIT CARD, volt meter (consisting of) 1

C50 000 348. CAPACITOR, tantalum 0.47 uf 35 volts 1

C51 038 585. CAPACITOR, mylar 0.22 uf 50 volts 1

C52 031 643. CAPACITOR, ceramic 0.01 uf 500 volts dc 1

C53 005 023. CAPACITOR, tantalum2.2 uf 20 volts 1

C54 071 229. CAPACITOR, electrolytic 470 uf 16 volts 1

D50,51 026 202. DIODE, rectifier 1 amp 400 volts straight polarity 2

DD5O-52 071 183. DISPLAY, LED numeric7 segment 3

1C50 071 239.INTEGRATED CIRCUIT, A/D connector 1

1C51 071 238.INTEGRATED CIRCUIT, decoder/driver 1

Q50-52 037 201. TRANSISTOR, 200 MA 40 volts PNP 3

R50 009 172. POTENTIOMETER, cermet trimmer 20 turn 0.5 watt 50K ohm 1

R51 03~ 848.POTENTIOMETER, cermet trimmer 25 turn 0.5 watt 10K ohm 1

R52 071 231. RESISTOR, metal film 0.5 watt 1 meg ohm 1

R53 071 237. RESISTOR, rnetalfilm0.Swattll0Kohm 1

R54 035 825. RESISTOR, carbon film 0.25 watt 1 K ohm 1

R55 039 327. RESISTOR, carbon film 0.25 watt 220 ohm 1

T50 071 617 .TRANSFORMER,currentll5volts 1

VR5O 071 248

072 944

081 381

. REGULATOR, voltage0.5 amps volts

.

HEAT SINK, voltage regulator. CONNECTOR, edge PC card

1

1

1

3 071 670 BRACKET, mounting - circuit card 1

4 070 026 STAND-OFF, No. 6-32 3

1

3.

OM-1 536 Page 4

�1 C -I 0 C)03 0

a, a, a,

-~ �3 -~ M

-I C)a-4 0 a.0 >

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure A2 Panel, W/Components (Fig A Pg 3 Item 60)

1 047 007 CIRCUIT CARD, voltage control (Fig A2A Pg 8) 1

2 006 426 BRACKET, mounting - capacitor 1

3 Cl 031 692 CAPACITOR, electrolytic 750 uf 200 voltsdc 1

4 010301 BUSHING,0.14IDx1/4ODx5/16 2

5 071 642 CIRCUIT CARD, motor speed (Fig A2B Pg 10) 1

6 RC5 073 730 CONNECTOR, edge 22 pin 1

7 026 837 INSULATOR, terminal - nylon 2

8 CR1 034 841 RELAY, 24 volts ac DPDT 1

9 009 335 STAND-OFF, No. 4-40 x 5/8 long 1/4 hex 2

10 072 993 PANEL, mounting - component 1

11 1 ,2T 038 659 BLOCK, terminal 20 amp 8 pole 2

12 T2 036 135 TRANSFORMER, control 115-24 volts ac 1

13 Ti 035 759 TRANSFORMER, control 115/36 volts 1

14 080 191 STRIP, insulator- block terminal 1

15 RC1O 079 784 CONNECTOR, circuit card 12 position 1

16 R3 079 497 RESISTOR, WW fixed 25 watt 2000 ohm 1

17 PLG2 079 797 HOUSING,terminal4 position 1

18 PLG1 079 798 HOUSING, terminal 13 position 1

19 RC4 079 783 CONNECTOR, circuit card 14 position 1

20 057 544 SPRING, compression 8

21 SRi 035 914 RECTIFIER, integrated 30 amp400 volts 1

22 VR1 046 685 VARISTOR, 0.6W 175 volts dc 1

23 Ri 030 651 RESISTOR, WWfixed 25 watt 10 ohm 1

24 PLG14 079 748 HOUSING, terminal 18 position 1

25 073 756 STAND-OFF, No. 6-32 4

OM-1536 Page 6

061

0

____

R57EJD6O

__

LILi

C52

A53 ~~R68

R59D58 R87

R55 ~D62

C68063

R89

R88

D55EJ

R73

0052

COMPONENTS TO BE


PERSONNEL ONLY

Figure A2A - Circuit Card, Voltage Control

TB-070 618

CR50

S

A BCDEFGHJKLMNOPOR S

~oOOOOOOOOOOOOOOOO o~

C55

U

C67ccD R51

C7Q

R84 R90 R61 R62

R52R92

R86

C50

R85

R8 1

059

R82

R79U

053 D51

00

C51

R94054 052

R69

R75U U

064

R53

C63

UD56

U

C62

051R60

R58

H 9c59C58

R91

C69

C60

_______

C57

C56 057 A52 R76 LIU

C66 R72~VR50~ IR65

R67

Page 7

Dia. Part


Figure A2A Circuit Card, Voltage Control (Fig A2 Pg 6 Item 1)

A50 052 133 AMPLIFIER, operationalquad74l 1

A51-53 009 159 AMPLIFIER, operational32/l6voltsdc 3

C50,60,69-71 000 340 CAPACITOR, ceramic 0.01 uf 50 volts 5

C51 028 294 CAPACITOR, mylar 1 uf 200 volts dc 1

C52 031 677 CAPACITOR, tantalum 5.6 uf 35 volts dc 1

C53,55-59,68 073 739 CAPACITOR, ceramic 0.1 uf 50 volts 7

C54 000 861 CAPACITOR, electrolytic 33 uf 35 volts 1

C61 005 023 CAPACITOR, tantalum 2.2 uf 20 volts 1

C62 009 577 CAPACITOR, tantalum 27 uf 35 volts 1

C63 053 992 CAPACITOR, ceramic 0.001 uf 1000 volts 1

C64,65 039 482 CAPACITOR, electrolytic 100 uf35voltsdc 2

C66,67 000 348 CAPACITOR, tantalum 0.47 uf 35 volts 2

CR50 048 028 RELAY, enclosed 120 volts ac 4PDT 1

079 843 FITTING, hose - ferrule 5/8 ID x 33/64 1

079 844 FITTING, hose - nut 5/8-18 left hand 1

D50 037 449 DIODE, zener 15 volts 1 watt straight polarity 1

D51 -54 026 202 DIODE, rectifier 1 amp 400 volts straight polarity 4

D55-64 028 351 DIODE, signal 0.02 amp 75 volts straight polarity 10

0C50 047 034 OPTO COUPLER, transistor - isolator 1

Q50 035 842 TRANSISTOR,6amp4ovoltsPNP 1

Q51 ,52 037 200 TRANSISTOR, 200 MA 40 volts NPN 2

R50 030 127 RESISTOR, carbon 2 watt 220 ohm 1

R51 .65,69,80,86,87 039 331 RESISTOR, carbon film 0.25 watt 4700 ohm 6

R52,78,91 ,93 035 888 RESISTOR, carbon film 0.25 watt 2200 ohm 4

R53,73 078 431 RESISTOR, carbon 0.25 watt 330 ohm 2

R54 039 332 RESISTOR, carbon film 0.25 watt 15K ohm 1

R55-57,64,67,76,84,85 035 827 RESISTOR, carbon film 0.25 watt 10K ohm 8

R58,61 039 336 RESISTOR, carbon film 0.25 watt 220K ohm 2

R59,60,63 035 826 RESISTOR, carbon film 0.25 watt 6800 ohm 3

R62,68,82 035 825 RESISTOR, carbon film 0.25 watt 1K ohm 3

R66,74 000 342 POTENTIOMETER, cermet trimmer 1 turn 0.5 watt 5K ohm 2

R71 ,72 006 424 POTENTIOMETER, cermet trimmer 1 turn 0.5 watt 2K ohm 2

R75,89 052 137 RESISTOR,carbonfilm0.25watt5.lKohm 2


R79 039 330 RESISTOR, carbon film 0.25 watt 3900 ohm 1



R88,92 081 833 RESISTOR, carbon film 0.25 watt 2.7 meg ohm 2



VR5O 081 832 REGULATOR, voltage 0.5 amp 15 volts 1

079 749 TERMINAL, header 18 position 1


OM-1536 Page 8

Figure A2B - Circuit Card, Motor Speed

TB-070 617

COMPONENTS TO BE


PERSONNEL ONLY

Page 9

A50-53

C50

C5 1

C52,61C53,62C54

C55,66-75,77C56

C57

C60

C63,64C65

CR50

D50-54,56-60D55

I C50

Q50,53Q5 1

Q52

R50

Note 1

R52 ,56,6 1

Note 2

R59

R60,87,88R64

R70

R73,83R78

R79

R80

R85

R86

T50

VR5O

VR5 1

Part

No.

009 159

039 482

031 699

073 739

035 833

005 023

031 643

073 549

031 677

035 561

031 694

031 721

081 797

026 202

080 910

081 800

037 200

037 824

039 355

030 839

035 827

052 138

035 884

030 007

039 335

039 331

049 015

039 328

039 108

039 106

035 886

030 937

030 090

036 143

081 799

047 272

079 843

079 844

NOTE 1: R51 ,53-55,57,63,67,68,74,75,81 ,82,84,89NOTE 2: R58,62,65,66,71 ,72,76,77,90BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.

3

1

1

2

2

1

12

1

1

1

2

1

1

10

1

1

2

1

1

1

14

3

9

1

3

1

1

2

1

1

1

1

1

1

1

1

1

1

Dia.

Mkgs. Description Quantity

Figure A2B 071 642 Circuit Card, Motor Speed (Fig A2 Pg 6 Item 5)

AMPLIFIER, operational 32/16 volts dc

CAPACITOR, electrolytic 100 uf 35 volts dc

CAPACITOR, mylar 0.0022 uf 200 volts dc

CAPACITOR, ceramic 1 uf 50 volts

CAPACITOR, mylar 0.033 uf 100 voltsdc

CAPACITOR, tantalum 2.2 uf 20 volts

CAPACITOR, ceramic 0.01 uf 500 volts dc

CAPACITOR, mylar 0.015 uf 200 volts

CAPACITOR, tantalum 5.6 uf 35 volts dc

CAPACITOR, mylar 4 uf 200 volts



RELAY, enclosed 24 volts ac 4PDT

DIODE, rectifier 1 amp 400 volts straight polarityDIODE, zener 15 volts 5 watt

INTEGRATED CIRCUIT, converter

TRANSISTOR, 200 MA4O volts NPN

THYRISTOR, SCR 7.4 amp 200 volts

TRANSISTOR, unijunction 15 MA 40 volts

RESISTOR, WWfixed 5 watt 220 ohm

RESISTOR, carbon film 0.25 watt 10K ohm


RESISTOR, carbon film 0.25 watt lOOK ohm

POTENTIOMETER, cermet trimmer 15 turn 0.75 watt 50K ohm

RESISTOR,carbon film 0.25 watt 47K ohm

RESISTOR, carbon film 0.25 watt 4700 ohm

RESISTOR, carbon film 0.25 watt 1 meg ohm





RESISTOR, carbon 0.5 watt 10 ohm


TRANSFORMER, pulse control

REGULATOR, voltage 8 volts

REGULATOR, voltage 12 volts

SOCKET, relaySPRING, hold down - relay

OM-1 536 Page 10

Item

No.

2

3

4

024 366

080 242

079 684

Figure A2A

5

1

1

1

Part


Figure A3 048 464 Timer Assembly (Fig A Pg 3 Item

-

61)

KNOB, pointer - line indicator

PLATE, indicator

BRACKET, mounting - timer

CIRCUIT CARD ASSEMBLY (Pg 12)

Fig

3

2

1

TB-080 368

Figure A3 - Timer Assembly


Page 11

A50-52

C50

C51 ,52,54C53 ,55C56

CR50-56

050-57,59-71D58

Q50-55

R50,64,68,76R51 ,81 -84

R52

R53,59,60,61 ,62,

65,71,72,73,77,80R54,63,69,70,78,79R55,56

R57,58,66,67,74,75

RC1

RC2

RC3

S50

009 159

039 482

005 023

031 677

073 714

027 810

079 843

026 202

037 449

073 535

039 332

048 466

030 018

605 912

079 795

079 793

079 794

079 722

079 844

Description

Circuit Card Assembly (Fig A3 Pg 11 Item 4)

Figure A3A - Circuit Card Assembly

3

1

3

2

1

7

7

21

1

6

4

5

1

11

6

2

6

1

1

1

1

7


OM-1536 Page 12

Dia.

Mkgs.

Part

No.

Figure A3A

Quantity

AMPLIFIER, operational 32 volts dc

CAPACITOR, electrolytic 100 uf 35 volts dc


CAPACITOR, tantalum 5.6 uf 35 volts dc


RELAY, enclosed 24 volts dc 4PDT

SOCKET, relayDIODE, rectifier 1 amp 400 volts straight polarityDIODE, zener 15 volts 1 watt straight polarityTRANSISTOR, 100 MA 30 volts NPN


POTENTIOMETER, WW slotted shaft 1 watt 1 meg ohm

RESISTOR, carbon 1 watt 820 ohm

035 827 RESISTOR, carbon film 0.25 watt 10K ohm

035 886 RESISTOR, carbon film 0.25 watt 22K ohm

035 823 RESISTOR, carbon film 0.25 watt 100 ohm


TERMINAL, header 13 pinTERMINAL, header 4 pinTERMINAL, header 3 pinSWITCH, toggle SPDT 4 amp 2-4 volts dc

SPRING, hold down relay

COMPONENTS TO BE


PERSONNEL ONLY

TB-080 371

RC16 079 737

Reed 079 687

604 525

057 091

+079 862

047 947

010 494

057 358

601 158

010 604

602 934

079 573

079 686

079 574

GS1 003 538

003 539

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


1

1

1 ft

1

1

1

2

2

2

2

1

1

1

2

1

1

Item Dia.

No. Mkgs.

Part


Figure B 070 183 Control, Gas

2

3

4

5

6

7

8

9

10

11

12

13

14

RECEPTACLE, square - flanged 16 pinRELAY, current (consisting of)

CORD, portable No. 18 2/c (order by ft)

SWITCH, reed SPST

WRAPPER

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

BUSHING,snapl ID1-3/8mtgholeBLANK, snap - in 7/8 inch

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

FITTING, pipe - galvanized coupling 1/4 NPT

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

CASE SECTION, bottom/front/sides

BRACKET, mounting - component

VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice (consisting of)

COIL, valve 115 volts ac open terminal

6

9

Figure B - Control, Gas

Ret: TC-O8O 365

Page 13

Part

No. Description

Attaching Hardware

602 066 SCREW, machine - truss hd 6-32 x 1/4


602 143 SCREW, self - tapping - round hd 6-32 x 3/8

602 071 SCREW, machine - round hd 6-32 x 1/2


602 075 SCREW, machine - round hd 6-32 x 1

602 078 SCREW, machine - round hd 6-32 x 2-1 /2

602 144 SCREW, self - tapping - round hd 8-32 x 3/8





604 804 SCREW, sheet metal - hex washer hd No. 8 x 3/8

604 434 SCREW, machine - round hd 1/4-20 x 2-1 /2

006 894 WASHER, lock - internal tooth No. 6

602 199 WASHER, lock - external tooth No. 6

602 200 WASHER, lock - split No. 8

602 203 WASHER, lock - split No. 10

602 207 WASHER, lock - split 1/4

605 196 NUT, self - locking hex 6-32

601 859 NUT, hex 6-32

601 860 NUT, hex 8-32

601 865 NUT, hex - full 1/4-20

Dia. Part


Parts For Optional Equipment

GS1 003 538 VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice (consisting of) or 1

+003 539. COIL, valve (Controls Co.) 1

GS1 080 841 VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice (consisting of) 1

+080 872.COIL, valve (Eemco) 1

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

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

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

080 581 COVER, locking - control box 1

080 584 TAB, locking 1

048 471 TOOL, extraction - pin 1

+When ordering coils be sure to provide manufacturers name.


OM-1536 Page 14

OWN R™S

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