Page 1
January
1996
Form:
OM-180
058
~i
Pow
Con
OPERATION
Effective
With
Serial
MANUAL
No.
KG057558
rypeofInput
Power
Volts
Phase
Amperes
50/60
AC
Hz
24
Single
3.5
Welding
Power
Source
Constant
Voltage
Constant
DC
With
Contactor
And
Control
Type
(CV)
Power,
14-Pin
~
1I~
PD22
GMAW
For
ipm
mpm)
Wire
Range
.023
(0.6
Max
Weight:
Wire
Feed
Speed
Range
or
75to630
To 16
(1.9
And
Diameter
To
5/64
2
To
mm)
Spool
60
lb
kg)
FCAW
in
(27
Welding
Welding
Circuit
Rating
100
500
Amperes,
100%
Duty
Volts,
Cycle
IP
Rating
P
23
Dimensions
Length:
in
Width:
Height:
CE
Overall
22-1/2
(572
mm)
10-1/2
(267
mm)
12
(305
mm)
Weight
in
32
lb
(14.5
kg)
in
8123
Miralani
(619)
PowCon
621-6300
incorporated
San
Drive,
FAX
Diego,
(619)
92126
CA
621-6301
Page 2
Page 3
Declaration
of
Conformity
for
European
N
OTE
Manufacturers
Manufacturers
Declares
con
forms
that
to
~
Name:
Address:
the
product:
the
following
Community
This
information
PowCon
8123
San
Directives
Electromagnetic
P
Miralani
Diego,
D22
and
is
provided
Incorporated
Drive
CA
Standards:
Low
Voltage
Compatability
92126
Directives
Directive:
for
units
USA
(EMC)
(CE)
with
CE
73/23/EEC
Directive:
certification
89/336/EEC
Products
label
(see
rating
on
unit).
European
Machinery
Contact:
Arc
Welding
Degrees
Insulation
Part
Directives:
89/392/EEC,
Equipment
Arc
Welding
of
Protection
Coordination
I:
Principles,
Equipment:
Electromagnetic
Mr.
Stewart
PowCon
Springfield
Wilmslow,
8K9
5AL
Brown,
(Europe)
House,
Cheshire
United
Standards
Part
1995
(April
1995
(May
Provided
For
Equipment
Requirments
Capatibility,
European
Water
Kingdom
91/368/EEC,
I:
Welding
Draft
Wirefeed
Draft
Enclosures
By
and
Sales
Lane
93/C
Power
Sources:
Revision)
Systems:
Revision)
(IP
Code):
With
Low-Voltage
Tests:
(EMC):
IEC
EN
Manager
133/04,
IEC
IEC
974-4
lEG
Systems:
664-1:1992
50199
93/68/EEC
974-1
529:1989
dec_coni
Telephone:
7/95
Fax:
44
44
1625525556
(0)
1625537553
(0)
Page 4
Page 5
SECTION
OM-1
80058
1/96
1-1.
Symbol
-
1
Usage
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
sat
ety_somi
4/95
4A
~
1-2.
Arc
The
symbols
hazards.
1.
2.
3.
4.
Do
Wear
Insulate
mats
the
Disconnect
information
Standards
qualified
operation,
not
work
safety
Safety
Only
During
servicing
OSHA
to
5.
Properly
Owners
6.
Always
now~r
~
NOISE
1.
Use
approved
1.
Keep
2.
If
inside,
remove
3.Ifventilation
4.
Read
manufacturers
cleaners,
Means
Warning!
procedure!
The
possible
Welding
a
When
ELECTRIC
Touching
shocks
circuit
The
circuits
semiautomaticorautomatic
wire
touching
Incorrectly
equipment
touch
hole-free
dry,
yourself
or
covers
or
ground.
input
this
CFR
29
install
Manual
verify
nord
ARC
NOISE
SLAG
Arc
visible
that
processes
grinding,
metal
FUMES
hazardous
Welding
these
health.
head
your
ventilate
welding
is
Material
the
and
WARNING
shown
see
you
given
listed
persons
keep
live
or
is
electrically
input
are
drive
reel,
the
live
electrical
insulating
from
big
enough
power
equipment.
1910.147
and
ground
and
national,
the
supply
orotind
wira
....
RAYS
can
OR
from
rays
and
burn
can
and
or
slag.
ear
plugs
produces
fumes
of
the
out
the
area
fumes
use
poor,
Safety
instruction
degreasers.
There
Out!
Watch
hazards
This
PARTS,
actionstoavoid
Hazards
below
the
symbol,
below
Section
in
should
are
is
install,
everybody,
SHOCK
electrical
burns.
severe
is
power
also
roll
welding
installed
hazard.
a
live
whenever
circuit
live
when
housing,
wire
or
parts.
and
gloves
and
work
to
or
ground
prevent
engine
stop
any
Lockout/tagout
Safety
(see
this
equipment
and
state,
ground
check
~~
is
WI
,JIJCI
can
IV
burn
.
damage
SPARKS
the
welding
invisible
eyes
can
welds
ear
or
AND
to
and
fumes.
and/or
and
gases.
an
approved
Data
for
process
(ultraviolet
and
damage
cooling
muffs
if
GASES
health.
your
fumes
can
gases
Do
not
use
Sheets
metals,
are
used
only
shown
group
watch
1-4.
are
possible
of
and
throughout
a
summary
Read
operate,
in
the
symbols
HOT
the
out,
and
hazards
adjoining
PARTS
hazards.
and
follow
maintain,
especially.children,
kill.
can
can
parts
The
electrode
the
and
machine
power
wire
welding,
and
all
are
electrically
improperly
body
protection.
using
dry
physical
before
input
power
Standards).
according
local
codes.
and
be
sure
~
uu,,,,cutcu
eyes
hearing;
can
injure
produce
and
Noise
hearing.
throw
level
gases.
be
hazardous
breathe
exhaust
(MSDSs)
infrared)
off
skin.
noise
and
air-supplied
consumables,
fatal
cause
and
work
is
is
metal
internal
on.
the
wire,
parts
live.
on.
output
grounded
insulating
with
contact
installing
according
to
that
input
rirotinri
to
.
and
skin;
FLYING
eyes.
intense
rays
from
some
Chipping,
pieces
is
high.
can
the
at
be
Breathing
to
your
fumes.
the
arc
respirator.
and
the
coatings,
In
or
its
of
to
symbols.
means
hazards.
this
follow
of
the
with
this
Warning!
Consult
manual
the
more
all
Safety
and
away.
terminal
properly
7.
When
conductor
8.
Frequently
replace
Turn
9.
Do
10.
cables.
11.
Do
If
12.
earth
with
13.
Do
ground,
14.
Use
damaged
15.
Wear
16.
Keep
17.
Clamp
WUI
AR
C
RAYS
2.
Wear
protect
Z49.1
Wear
3.
Use
4.
and
5.
Wear
material
5.
Work
wearing
watchperson
and
breathing
Do
6.
operations.
form
7.
Do
cadmium
weld
wearing
containing
Watch
symbols
call
to
related
complete
Standards.
repair
disconnect
in
grounded
making
first
inspect
cord
immediately
oft
all
equipment
not
use
not
drape
grounding
a
separate
touch
not
another
or
well-maintained
only
parts
a
safety
all
panels
work
or
fl4J101,O
.
a
welding
face
your
Z87.1listed
and
approved
protective
warn
glare;
protective
(wool
confined
in
a
an
the
lower
air
in
weld
not
The
toxic
highly
weld
not
plated
the
area,
an
air-supplied
these
Marks
A
Means
~
Out!
possible
and
related
attention
instructions
safety
this
unit.
boxorthat
receptacle
connections,
input
double-check
input
power
if
when
worn,
damaged,
cables
over
your
of
the
workpieceisrequired,
cable
do
electrode
Maintain
once.
if
covers
with
as
flIQIj~C
helmet
fitted
and
eyes
in
glasses
or
not
clothing
leather)
space
Welding
level
near
and
and
irritating
coated
metals,
unless
steel,
is
well
respirator.
elements
if
working
Safety
made
rays
electrode
at
harness
and
cable
~
YVU,
safety
screens
others
and
air-supplied
nearby.
oxygen
is
safe.
locations
heat
on
area
a
special
safety
not
NOTE;
safety
ELECTRIC
instructions
to
and
to
avoid
identify
information
cord
outlet.
connections.
cord
damaged
not
plug
attach
for
damage
bare
in
use.
undersized,
body.
work
not
you
use
are
from
in
contact
different
a
clamp
equipment.
unit
according
above
floor
securelyinplace.
metal-to-metal
good
th~
n~ar
when
wAld
a
as
proper
__.
with
weldingorwatching
Standards).
with
side
shields.
barriers
to
to
and
only
respirator.
causing
ventilated,
can
protect
watch
the
arc.
from
durable,
foot
protection.
if
it
is
well
Always
fumes
and
gases
injury
degreasing,
of
the
arc
can
gases.
such
coating
The
give
as
and
coatings
off
toxic
the
or
cleaning,
message.
related.
for
necessary
MOVING
SHOCK,
below
possible
the
hazard.
found
is
connected
grounding
proper
bare
or
can
wiring
or
poorly
it
ground
work
or
with
the
machine.
or
Repair
manual.
to
level.
contact
IJIfl(.#II%,QI.
shade
of
(see
from
others
flame-resistant
ventilated,
haveatrained
can
displace
death.
Be
or
with
react
galvanized,
is
if
removed
necessary,
and
any
fumes
if
OM.180058
vapors
welded.
The
in
the
to
a
wiring
kill.
spliced
directly
cable.
work,
replace
to
filter
to
ANSI
flash
while
or
air
the
sure
spraying
to
or
lead,
from
the
while
metals
Page
I
I
I
1
Page 6
1.
2.
3.
1.
2.
3.
4.
Protect
mechanical
Install
cylinders
support
cylinders
Keep
circuits.
Protect
yourself
Do
weld
not
Remove
is
not
this
Be
alert
easily
go
CYLINDERS
Shielding
pressure.
Since
process,
compressed
shocks,
in
or
an
cylinder
away
WELDING
explosion.
Welding
drums,
can
fly
hot
workpiece,
and
burns.
objects
fire.
or
doing
and
where
all
flammables
possible,
that
welding
small
through
can
cylinders
gas
If
damaged,acylinder
to
sure
cylinders
open
position
to
prevent
from
any
can
closed
can
the
and
Accidental
cause
sparks,
be
and
from
sparks
within
35
cover
and
cracks
and
are
treat
flames,
cause
welding
hot
can
them
hot
cylinders
gas
be
gas
slag,
upright
rack
on
or
pipes,
from
off
can
Check
welding.
any
others
flying
tightly
sparks
explode
contain
normally
them
by
falling
welding
containers,
equipment
contact
sure
flying
strike
ft
(10.7
materials
if
gas
part
carefully.
from
excessive
and
sparks,
securing
or
tipping.
other
or
cause
such
themtoblow
The
arc.
can
of
electrode
explosion,
the
area
and
sparks
flammable
of
the
m)
with
approved
from
damaged.
can
of
to
flying
overheating,
is
welding
welding
openingstoadjacent
under
high
explode.
the
welding
heat,
arcs.
a
stationary
electrical
fire
or
as
tanks,
Sparks
up.
sparks,
fires
cause
metal
to
safe
before
hot
metal.
material.
arc.
covers.
can
areas.
4.
Never
5.
Never
6.
Never
7.
Use
only
fittings
associated
8.
Turn
9.
Keep
in
use
Read
10.
associated
Standards.
5.
Watch
6.
Be
aware
cause
can
7.
not
Do
pipes,
(see
8.
Connect
practical
unknown
9.
not
Do
10.
Remove
11.
12.
contact
Wear
shirt,
Remove
from
If
a
drape
allow
a
welding
weld
on a
correct
designed
parts
face
away
protective
connected
or
follow
and
equipment,
for
tire,
that
welding
fire
weldonclosed
unless
they
Standards).
Safety
work
cable
to
prevent
paths
welder
use
stick
electrode
when
tip
oil-free
protective
cuffless
trousers,
combustibles,
any
your
person
torch
welding
electrodetotouch
pressurized
shielding
for
the
specific
in
good
from
valve
in
place
cap
for
use.
instructions
and
and
on
keep
the
are
to
a
on
hidden
containers
properly
the
welding
and
causing
thaw
to
from
in
not
use.
garments
high
before
over
cylinder
cylinders,
gas
application;
condition.
outlet
over
on
CGA
publication
tire
extinguisher
a
ceiling,
side.
prepared
work
as
current
electric
frozen
holder
shoes,
such
as
doing
any
a
cylinder.
gas
cylinder.
any
explosion
regulators,
maintain
when
opening
valve
except
compressed
P-i
nearby.
floor,
bulkhead,
such
as
tanks,
according
closetothe
from
traveling
shock
and
pipes.
off
cut
or
suchasleather
and
a
cap.
butane
a
lighter
welding.
will
hoses,
them
cylinder
when
cylinder
cylinders,
gas
listed
or
drums,
AWS
to
welding
long,
fire
hazards.
welding
gloves,
or
matches,
result.
and
and
valve.
is
in
Safety
partition
or
F4.
1
area
as
possibly
wire
at
heavy
1-3.
Additional
FIRE
placing
combustible
Do
1.
surfaces.
Do
2.
FALLING
serious
damage.
Use
1.
gas
Use
If
long
unit.
HOT
Do
1.
Allow
2.
torch.
MOVING
1.
Keep
2.
Keep
and
MAGNETIC
CURRENTS
operation.
Pacemaker
1.
Wearers
2.
near
operations.
Installation,
OR
EXPLOSION
unit
locate
not
install
not
personal
lifting
cylinders,
equipment
lift
using
enough
PARTS
touch
not
cooling
PARTS
away
all
doors,
securely
should
arc
on,
surfaces.
unit
on,
unit
near
EQUIPMENT
lift
to
eye
or
any
of
adequate
to
forks
extend
to
can
cause
hot
parts
period
can
from
moving
panels,
in
place.
FIELDS
can
wearers
consult
welding,
injury
move
Operation,
result
can
over,
near
or
over,
flammables.
can
and
only,
unit,
beyond
bare
before
cause
parts
covers,
affect
away.
their
NOT
accessories.
capacity
be
opposite
severe
handed.
working
injury.
suchasfans.
and
FROM
doctor before
or
unit
other
keep
gouging,
And
from
near
or
combustible
cause
equipment
running
gear~
unit.
lift
to
forks
sure
are
side
burns.
on
gun
closed
guards
HIGH
pacemaker
going
welding
spot
Maintenance
MOVING
1.
2.
FLYING
injure
1.
WELDING
wounds.
4
of
or
~QHF)JJ,
1.
2.
HIGH-FREQUENCY
interfere
services,
communications
1.
2.
3.
4.
5.
Hazards
PARTS
Keep
away
Keep
away
PIECES
eyes.
Wear
safety
shield.
WIRE
Do
not
press
Do
not
point
or
people,
Have
electronic
The
electrician
problem
If
using
Have
maintained.
Keep
tightly
and
possibility
any
with
only
equipment
is
user
resulting
notified
by
the
equipment
the
high-frequency
shut,
use
grounding
of
can
trom
moving
from
pinch
OF
glasses
can
trigger
gun
toward
gun
metal
when
radio
computers,
equipment.
qualified
perform
responsible
promptly
from
the
FCC
at
installation
keep
spark
and
interference.
cause
injury.
parts.
such
points
METAL
with
until
any
threading
as
or
side
shieldsorface
cause
instructedtodo
the
of
part
welding
RADIATION
navigation,
persons
for
correct
the
about
once.
regularly
source
gaps
shielding
familiar
installation.
this
havingaqualified
any
installation.
interference,
checked
doors
correct
at
to
drive
rolls.
DIRT
can
puncture
so.
other
body,
wire.
can
safety
and
with
interference
stop
and
and
panels
setting,
minimize
the
OM-180058
Page
2
Page 7
OVERUSE
EQUIPMENT.
Allow
1.
2.
cooling
Reduce
starting
Follow
3.
circuit
Put
on
boards
Use
proper
move,
ELECTRICITY
STATIC
on
1.
2.
can
period.
current
weld
to
rated
duty
boards.
grounded
or
parts.
static-proof
PC
or
ship
cause
or
again.
cycle.
wrist
boards.
reduce
strap
bags
OVERHEATED
duty
can
damage
BEFORE
and
cycle
boxes
before
par
handling
to
SIGNIFICANT
removal
1.
of
Off
Turn
discharge
instructions
~g
DC
input
inverter,
input
in
parts.
any
SHIELDING
ng
VOLTAGE
power
disconnect
capacitors
Maintenance
supply
gas
exists
inverters.
on
input
Section
GAS
when
after
power,
according
before
harm
can
in
not
use.
and
to
1-4.
Principal
Safety
American
Safety
in
Welding
and
Superintendent
Washington,
Recommended
of
Cutting
American
Welding
National
Protection
1-5.
Considerations
Electric
The
of
Effects
Society,
Electrical
EMF
And
following
U.S.
the
of
Welding
Association,
Congress,
Background
Government
volume
large
cellular
level
establish
produce
very
understanding
single
allow
risk
or
high
or
avoid
that
changes
coherent
to
us
offer
to
potential
Safety
Welding
Containers
quality,
draw
and
Society,
Health
Standards,
of
Documents,
D.C.
20402.
Safe
Practices
Society
550
N.W.
Code,
Information
About
is
a
quotation
Paper,
of
scientific
from
low
frequency
in,
does
framework.
definite
science-based
clear
risks.
Welding
Office
Frequency
Office,
studies
biological
the
not
Magnetic
Power
Printing
and
Standards
Cutting,
N.W.
550
U.S.
for
Have
That
Standard
LeJeune
NFPA
Standard
Batterymarch
And
Fields
from
the
of
Technology
OTA-BP-E-53
results
yet
Electric
May
1989):.
findings
with
animals
magnetic
systems.
are
allow
us
Even
conclusions
more
ANSI
Standard
LeJeune
OSHA
Government
the
Preparation
Held
Hazardous
AWS
Rd,
Miami,
Park,
The
Effects
General
Assessment,
&
(Washington,
based
and
fields
While
complex.
to
interpret
frustrating,
about
advice
on
Miami
Rd,
CFR
29
Printing
for
from
F4.1,
FL
33126
from
70,
Quincy,
Of
Low
Conclusions
MA
Magnetic
there
is
. .
on
experiments
people
interact
can
of
most
Current
the
it
questions
strategies
from
Z49.1,
FL
33126
from
1910,
Office,
and
Welding
Substances,
American
National
Fire
02269.
Frequency
Section
Biological
Fields
DC:
U.S.
now
a
very
the
at
which
clearly
and
with,
this
work
is
scientific
evidence
does
not
of
possible
minimize
to
in
yet
of
a
Safe
Handling
from
P-i,
Highway,
Code
from
Rexdale
Safe
Compressed
Suite
for
SafetyinWelding
Canadian
Boulevard,
Practices
Protection,
Standards
Cutting
National
MA
To
Institute,
And
Fire
02269.
reduce
procedures:
1.
2.
3.
4.
cables
Keep
Arrange
Do
not
Keep
welding
coil
practical.
Connect
5.
possible.
Pacemakers:
About
above
The
wearers.
Consult
of
Compressed
501,
Arlington,
Standards
Rexdale,
For
Occupation
ANSI
Standard
1430
Welding
Protection
magnetic
cables
work
fieldsinthe
close
together
to
one
or
drape
power
clamptoworkpiece
procedures
doctor
your
Gases
Gas
Association,
VA
22202.
and
Cutting,
Association,
Ontario,
And
Z87.1,
Broadway,
Processes,
Association,
by
twisting
side
and
cables
around
and
source
also
for
complete
recommended
are
in
Cylinders,
1235
CSA
Standards
Canada
M9W
Educational
from
New
NFPA
American
York,
Standard
Batterymarch
workplace,
or
taping
from
the
body.
closetothe
as
information.
the
away
cablesasfar
CGA
Jefferson
Standard
I
Eye
NY
10018.
Park,
the
use
them.
operator.
away
for
Pamphlet
Davis
Wi
17.2,
Sales,
R3.
And
Face
National
from
51
B,
Quincy,
following
as
weld
as
pacemaker
178
OM-1
80058
Page
3
Page 8
SECTION
2-
DEFINITIONS
2-1.
Warning
Label
Definitions
Warning!
possible
symbols.
Drive
rolls
Welding
welding
hands
keep
away.
Electric
1
Wear
1.1
Do
not
bare
or
damaged
.2
Protect
1
shock
from
Disconnect
1.3
power
machine.
2
Breathing
be
hazardous
2.1
Keep
fumes.
2.2
Use
exhaust
2.3
Use
fumes.
3
Welding
explosion
3.1
Keep
welding.
flammables.
3.2
Welding
fires.
nearby,
watchperson
Do
not
3.3
closed
Arc
4
injure
4.1
Wear
Use
shirt
helmet
filter.
protection.
Become
5
instructions
the
on
Do
not
6
(cover)
Out!
Watch
hazardsasshown
can
injure
fingers
and
and
shock
dry
insulating
touch
hand.
drive
during
metal
can
electrode
Do
not
wire
voltage
gloves.
yourself
by
work
before
your
forced
ventilating
flammables
Haveafire
and
from
insulating
and
ground.
input
plug
working
welding
to
your
head
out
ventilationorlocal
to
remove
fan
can
sparks
fire.
or
Do
weld
not
can
sparks
extinguisher
have
ready
weldondrums
containers.
burn
can
rays
skin.
and
hat
ear
collar.
Wear
safety
protection
Use
with
correct
complete
trained
before
machine
remove
or
label.
the
welding
and
or
There
by
are
parts
operation
objects
kill.
gloves.
with
wet
wear
electric
yourself
or
on
fumes
can
health.
of
the
the
fumes.
to
remove
cause
from
away
near
cause
a
to
use
or
any
and
eyes
glasses.
and
button
of
shade
body
the
read
working
welding.
over
paint
are
the
at
it.
OM-180058
Page
4
Page 9
SIN:
Model
KG111111
115
396
P022
2-2.
Symbols
NOTE
~
And
U1=24
3.5
11=
U2=
Definitions
Some
symbols
MILLER
V\.~
A
100
V
ELECTRIC
are
12=
MEG.
found
500
CO.,
1\.
A
APPLETON,
only
on
50/60
IP
23
X
100
WI
USA
CE
products.
Hz
%
ST-us
794-A
OM-180058
Page
5
Page 10
3-1.
Site
Selection
SECTION
3-INSTALLATION
3-2.
GMAW
FCAW
OM-180058
Gun
Recommendation
Process
Corded
Hard
or
Self-Shielding
6
Page
Wires
Wires
Table
Gun
M25
GA-4OGL
Or
M40
Page 11
3-3.
Equipment
Connection
Diagrams
3-4.
3-5.
*The
Connecting
Tools
Needed:
z~
5/8,11/l6in
14-Pin
REMOTE
remaining
pins
Plug
14
not
are
14-Pin
Plug,
Information
~j~*
A
B
G
C
D
E
used.
Shielding
24
voltsacwith
Contact
Circuit
+10
0
Remote
to
closuretoA
common.
volts
control
volts
+10
dc
respect
output
circuit
dc
input
And
Gas
socket
to
completes
to
remote
common.
command
Optional
Pin
G.
24
volts
control
with
signal
Information
contactor
ac
respect
from
remote
Volt
socket
to
control
Sense
control
1
Gas
hand
tomer
2
14
Use
plug
welding
3
Optional
(Part
Connect
circuit.
D.
with
respect
Lead
Hose
Thread
Supplied)
Pin
Plug
to
power
Volt
Of
Meter
work.
to
With
make
source.
to
PLG2
socket
OM-180058
5/8-18
Fittings
connection
Lead
Sense
Option)
ST-156
D.
Right-
(Cus
to
272-B
Page
7
Page 12
3-6.
Connecting
Welding
Gun
And
Weld
Cable
Tools
Needed:
~
5/8,9/l6in
1
Gun
Securing
Gun
2
3
Loosen
Position
as
Block
Outlet
Gun
knob,
outlet
possible
touching.
4
Gun
Trigger
Gun
5
6
7
Trigger
Weld
Weld
Power
Wire
insert
wire
drive
to
Tighten
Plug
Cable
Terminal
From
Cable
Source
Knob
Guide
into
gun
as
guide
rolls
knob.
without
Receptacle
Welding
block.
dose
3-7.
Setting
Time
Range
For
Optional
Spot
Time
Control
ST-155
246-B
OM-180058
Page
8
Page 13
3-8.
Installing
And
Aligning
Wire
Guide
And
Drive
Roll
Install
and
Install
drive
click.
nut
one
drive
Only
adjustment
in
groove
wire
guide
Remove
grooves
drive
using
rolls
gear
screw
drive
as
secure
shown.
a
wire
and
turn
is
adjustable.
in
or
roll
lines
and
rolls,
wire
brush.
guide.
drive
out
up
roll
Turn
until
with
clean
Tools
Needed:
3/16
r
in
3/8in
OM-180058
Page
9
Page 14
3-9.
Installing
And
Threading
Welding
Wire
If
necessary,
of
for
Install
Adjust
when
3
Lay
Open
wire
wire
Close
bly.
comes
To
gun
wood
wire
Cut
use
wire
tension
wire
cable
gun
pressure
tightly,
through
and
Press
out
adjust
trigger
surface.
does
off
wire.
different
feed
tighten
drive
not
move
spool.
nut
stops.
out
and
guides
Jog
gun.
roll
feed
to
Tighten
slip.
Close
hub
on
size
wire
wire
so
straight.
assembly,
off
cut
end.
into
gun.
pressure
until
button
pressure,
wire
door.
support
spool.
is
taut
hold
Push
assem
wire
press
against
knob
so
OM-180058
Page
Tighten
DI
Ill
Tools
Needed:
r
15/l6in
ST-155
Ref.
10
244-C/S-0627-A
Page 15
SECTION
4
OPERATION
4-1.
Front
Panel
Li
Controls
0
I
6
1
Optional
Meter
2
Optional
Switch
Use
speed
3
Optional
II
2
3
/
5
/
4
Li
Control
Use
voltage
bers
Wire
4
5
Purge
Use
valve
just
gas
Power
6
7
Jog
Use
wire
control
circuit
Voltage/Wire
Voltage/Wire
choose
to
display.
Remote
to
set
welding
the
at
for
reference
are
Speed
Switch
to
momentarily
to
purge
regulator.
Switch
Switch
to
momentarily
at
speed
without
or
shielding
volts
wire
Control
air
set
energizing
or
Voltage
power
feeder.
only.
energize
from
gun
feed
Wire
on
valve.
gas
Speed
Speed
wire
source
Num
or
welding
Speed
welding
feed
gas
ad
4-2.
Optional
2
Side
Panel
Controls
Pref
low
1
Control
sets
wire
welding
Postf
2
Control
low
sets
completion
Bumback
3
Control
adjusts
energized
4
Switch
ous
5
Factory
spot
desired,
Close
Continuous
Spot
selectsanuntimed
weld
or
Time
Spot
set
time.If0.12
see
side
Control
time
is
energized.
Control
time
of
bumback.
Control
time
after
wire
timed
a
Control
for
0.25to5
Section
door.
gas
gas
welding
feed
spot
2.5
to
ST-155
flows
flows
Switch
seconds
seconds
3-7.
before
after
wire
stops.
continu
weld.
245
is
of
is
OM-180058
ST-155
243-C
Page
11
Page 16
SECTION
5-
MAINTENANCE
TROUBLESHOOTING
&
5-1.
Routine
Maintenance
5-2.
Overload
Protection
Off
A
Turn
welding
engine
wire
power
on
feeder
source.
and
Stop
welding
generator.
1
Fl
load.
2
CB1
Correct
set
Close
2
Fl
Fuse
protects
Replace
Circuit
protects
problem
breaker.
and
wire
Fl
Breaker
motor
latch
feeder
if
and
door.
from
open.
CB1
from
overload.
manually
over
re
OM-1
80058
Page
ST-155
243-BIRef.
12
ST-800
185-A
Page 17
5-3.
Troubleshooting
~*HdH
Trouble
Wire
does
not
feed,
unit
operative.
Wire
does
feeds
Wire
feeds
Wire
but
not
feeds
Wire
Wire
pressed
is
ger
valve
Gas
feed.
not
erratically.
when
when
gun
as
soon
does
not
but
continuestofeed
released.
rattles
Jog
triggerispressed.
as
feed
loudly
slowlyorerratically.
Gas
does
not
flow;
wire
completely
switch
is
is
power
until
trigger
and
wire
feeds.
in-
pressed
applied.
after
trig
feeds
Turn
Check
Check
Check
Check
~
Check
ers
Have
Readjust
Use
Clean
Remove
Replace
Have
Check
ers
Check
Check
is
Check
Check
Power
fuse
14pin
input
circuit
gun
Manual.
Factory
correct
or
replace
weld
contact
Factory
gun
Manual.
gun
for
for
gas
switch
Fl
and
plug
power.
breaker
trigger
Authorized
hub
tension
size
spatter
Authorized
trigger
trigger.
short
short
valve
On.
replace
PLG2
CB1
connection
and
drive
or
dirty
around
tube
or
connection
See
between
between
and
flowmeter.
if
necessary
connections.
and
at
Service
drive
roll
(see
worn
liner.
Service
at
Owners
gun
trigger
gun
trigger
gun
~
fuse
wire
roll
Parts
drive
nozzle
See
wire
Fl.
feeder.
Agent
pressure
Listing)
roll
opening.
Owners
gun
Agent
feeder.
Manual.
leads
leads
(see
(see
check
(see
check
Remedy
Section
Section
Check
drive
(see
Section
drive
Check
and
and
gun
Section
Manual.
gun
weld
weld
5-2).
5-2)
trigger
motor
3-8).
motor
trigger
cable.
cable.
leads
and
3-9).
and
leads
Repair
Repair
and
control
control
and
or
or
trigger
board
board
trigger
replace
replace
switch.
PCi.
PCi.
switch.
gun
gun
See
See
trigger
trigger
gun
gun
leads.
leads.
Own
Own-
OM-180058
Page
13
Page 18
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Page 19
SECTION
7-
PARTS
LIST
Item
No.
1
2
....
3
....
4....
5
....
6
....
7
....
8....
9....
10....
...11....
12....
13....
14....
Part
Fig7-2
072094
058427
141700
605941
154098
010233
057971
010191
058628
058428
135205
134306
137461
108008
168103
+168
166594
124900
No.
104
Figure
CONTROL
HUB
&
RING,
RING,
WASHER,
SHAFT,
SPRING,
WASHER,
WASHER,
WASHER,
HUB,
NUT,
FOOT,
BASE
REEL,
NUT,
RETAINER,
LABEL,
SUPPORT,
Main
7-1.
BOX
SPINDLE
retaining
retaining
stl
flat
support
spool
cprsn
flat
stl
fbr
.656
brake
spool
stl
rbr1.25Odia
wire
spanner
hex
slflkg
(consisting
retaining
spool
caution
reel
Assembly
ASSEMBLY,
spool
shaftx.O5Othk
.625
ID
.640
OD
.970
1.SOOdia
keyed
ID
1.500
x
stl
.625-11
reg
1.375
x
of)
support
falling
support
Description
(consisting
OD
1.000
x
wirex1.250
.120
x
.l25thk
x
00
.l25thk
x
w/nylon
high
(consisting
wire
reel
can
x
l4ga
insert
of)
cause
of)
thk
damage
Quantity
1
1
1
1
1
1
1
1
2
2
1
1
4
1
1
1
1
1
1
OPTIONAL
+When
SURE
BE
ordering
PROVIDE
TO
7-2
Fig
a
component
originally
MODEL
AND
Figure
displaying
SERIAL
NUMBER
Main
7-1.
a
precautionary
Assembly
WHEN
label,
ORDERING
the
2
label
14
should
REPLACEMENT
A
13
alsobeordered.
PARTS.
OM-180058
ST-124
942-C
Page
15
Page 20
Co
CO
CO
/
0)
-
to
0
OM-180058
Page
(\1
01
to
to
Co
01
CO
U,
7-2.
Figure
Control
Box
to
Cv,
to
ST-134
909
16
Page 21
Item
No.
Dia.
Mkgs.
Part
No.
Figure
7-2.
Control
Description
Box
(Fig
7-1
Item
Quantity
1)
1
2
3
4
5
6
7
9
10
12
13
14
15
Fl....
17
18
...22....GS1....
25
...26....CB1....
.29...
30
31
...32
33
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PLG3...
PLG4...
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PLG16.
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113
115
113
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227
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162
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772
219
111
454
093
746
092
746
746
055
SCREW,
STOP,
SPACER,
PIN,
LEVER,
PIN,
KNOB,
SPRING,
WASHER,
FASTENER,
SCREW,
WASHER,
INSULATOR,
INSULATOR,
WASHER,
NUT,
FUSE,
HOLDER,
BUSHING,
WIRE
NUT,
GUIDE,
PLATE,
HOSE,
VALVE,
CATCH,
PLATE,
LABEL,
WRAPPER
BUMPER,
LABEL,
CIRCUIT
NUT,
CABLE,
CONNECTOR
.250-20
cover
gear
hair
cotter
mtg
pressure
hinge
adjustment
cprsn
cupped
.250-20
shldr
flat
stl
hex
jam
mintr
gI
fuse
snap-in
GUIDE
term
jack
wire
ident
SAE
.187
24VAC
link-lock
keeper
warning
polyurethane
warning
BREAKER,
hex
nyl
No.
18
pinned
housing
contactor
nylafil
slo-blo
&
inlet
control
jam
&
CONNECTOR,
CONNECTOR,
univ
nprn
lead
50A
brd
mot
CLAMP,
HOSE,
WIRE,
CONNECTOR,
BLOCK,term2OA6P
LINK,
jumper
CAPACITOR,
CLAMP,
CIRCUIT
CONNECTOR
term
elctlt
capacitor
CARD,
&
CONNECTOR,
CONNECTOR
&
CONNECTOR,
CONNECTOR
&
CONNECTOR,
STAND-OFF
CIRCUIT
CONNECTOR
SUPPORT,
CARD,
&
CONNECTOR,
CONNECTOR
&
CONNECTOR,
1.250
x
.054x.750
gear
tension
OD
.770
stl
.328
hexwhd
50
x
.363
nyl
drive
.625
.500-13
7A
mintr
.250
nyl
inlet
NUT,
black
rcpt
panel
ID
.41000
x
2
custom
way
link-lock
general
electric
man
.75ONPST
6/c
(order
PINS,
circ
pin
circ
clamp
No.
1
x
(order
l4ga
cable
clamp
blk
20A
5000uf
1
.375dia
motor
SOCKETS,
skt
rect
SOCKETS,
skt
rect
SOCKETS,
skt
rect
meter
SOCKETS,
skt
rect
SOCKETS,
skt
rect
hd
.105
ID
x
x
1.250
x
.194
1.250
ID
hex
wire
.812
x
panel
1
.75Omtg
soc
x
OD
case
ID
x
1.375
(consisting
(order
by
(orderbyft)
1/8
port
precautionary
polymer
shock
by
(consisting
push-in
.250
and
reset
if)
rlf
str
ID
(orderbyif)
by
if)
.500
50V
.500sq
pinch
P
4A
1
of)
14-l8ga
sz
clip
speed
control
(consisting
24-l8ga
Molex
(consisting
24-lBga
Molex
(consisting
8ga
card
Molex
24-1
PC
(consisting
24-l8ga
Molex
(consisting
8ga
Molex
24-1
gr
x
OD
ID
OD
model
17-20
1.225
x
of)
orf
8
.125
x
.703
1.000
x
mtg
hole
and
adh
back
25OVAC
Amp
Amp
of)
39-00-0038
of)
39-00-0038
of)
39-00-0038
of)
39-00-0038
of)
39-00-0038
serial
21
3603-1
206322-2
number)
OM-180058
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2ff
1
1
1
1
1
1
1
1
1
11ff
1
14
1
1
1ff
15ff
1
1
1
1
1
1
1
6
1
10
1
10
2
1
1
8
1
5
Page
17
Page 22
Item
No.
Dia.
Mkgs.
Part
No.
Figure
7-2.
Control
Description
Box
(Fig
7-1
Item
1)
(Continued)
Quantity
42
44....
46
47....
50
...51....RC2....
...52
53
54
Mi
S3
Ri
S2
Si
56
57
58
60
62
63
...64
65
66
...68
69
.115
443
136
339
134201
605308
092865
122741
....
*136
745
079625
113333
073562
....
011232
152728
090440
048282
079534
057359
097922
111997
107983
079624
602213
010910
057084
010224
172391
079633
601872
604538
124778
172076
121271
172075
120304
STAND-OFF,
..
COVER,
..
STAND-OFF
RING,
stl
KEY,
MOTOR,
BRUSH
WASHER,
SWITCH,
POTENTIOMETER,
SWITCH,
CASEASSEMBLY
INSULATOR,
CONNECTOR
CONNECTOR,
NAMEPLATE
BLANK,
KNOB,
SWITCH,
BLANK,
SCREW,
WASHER,
WASHER,
BUSHING,
PIN,
spring
HOUSING,
FITTING,
stl
NUT,
WASHER,
KNOB,
CARRIER,
SCREW,
CARRIER,
BLANK,
6-32
opening
SUPPORT,
retaining
.i215/.1230x.750
gear
&
SPRING
spring
PB
MC
PB
SPDT
cover
snap-in
pointer
rocker
snap-in
stl
cap
lock
flat
snap-in
CS
adapter.gun/teeder
hose
full
hex
flatstl
T
plstc
drive
.250-20
drive
snap-in
.750
x
meter
stl
NO
122RPM
ASSEMBLY
.500
SPST
sltd
C
24VDC
housing
w/SOCKETS,
circ
skt
(order
by
nyl
.375mtg
.875dia
stl
stl
.187x1.000
brs
1.000
x
SPST
nyl
.SOOmtg
hexhd
.375
split
SAE
.375
.250
nyl
barbed
.375-16
SAE
.312
Ig
roll
w/components
.500
x
roll
w/components
nyl
.25Omtg
Ig
when
used
(not
PC
card
(consisting
shakeproof
115VAC
1A
sfti/T2W10K
(consisting
push-in
model
.250
iOA
slflkg
.312-18x2.000
x
soc
and
hole
ID
VAC
250
hole
.375-16
ID
x
nipple
hd
hex
hole
14-l8ga
.375mtg
3/l6tbg
serial
2.250
x
8
gr
unit
has
of)
ohm
of)
Amp
number)
hole
bar
Meter
66358-6
Kit)
2
1
2
1
1
1
2
2
1
1
1
1
1
1
4
1
1
1
1
I
~1
2
2
1
1
1
1
1
1
1
1
1
1
6
*Recommended
+When
Part
BE
OM-180058
ordering
of
SURE
152
TO
Page
Spare
a
212
Optional
PROVIDE
18
Parts.
component
Digital
MODEL
originally
Meter
AND
displaying
V/WFS
SERIAL
a
precautionary
NUMBER
WHEN
label,
ORDERING
the
label
should
REPLACEMENT
also
be
ordered.
PARTS.
Page 23
N
OTE
Fraction
.023/.025
.030
.035
.045
.052
1/16
in.
in.
in.
in.
in.
in.
Wire
~
Diameter
Decimal
.023/.025
.030
.035
.045
.052
.062
in.
in.
in.
in.
in.
Base
1.
2.
3.
4.
5.
in.
7-1.
Table
selectionofdrive
V-Grooved
U-Grooved
U-Cogged
V-Knurled
Drive
V-Knurled
rolls
rolls
rolls
rolls
roll
types
rollincombination
Metric
0.6
mm
0.8
mm
0.9
mm
1.2mm
1.3
mm
1.6mm
Drive
Roll
And
Wire
rolls
for
hard
for
soft
for
extremely
for
hard
may
shelled
be
upon
wire.
and
mixed
the
soft
soft
with
.
Kit
No.
131
087
594
079
079 595 053 700
596
079
079 597
079
598
Guide
Kits
following
shelled
shelled
cored
to
cored
wires
wires.
suit
particular
U-Grooved).
Drive
Part
No.
087
130
053
695
053
697
053
698
053 699
recommended
wires.
(usually
requirements
Roll
Type
V-Grooved
V-Grooved
V-Grooved
V-Grooved
V-Grooved
V-Grooved
usages:
hard
surfacing
types).
(example:
Inlet
Wire
056
056
056
056
056
056
Guide
192
192
192
193
193
195
.035
.045
.052
1/16
5/64
.035
.045
.052
1/16
.068-.072
5/64
.045
.052
1/16
5/64
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
.035
.045
.052
.062
.079
.035
.045
.052
.062
.068-.072
.079
.045
.052
.062
.079
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
0.9
1.2mm
1.3
1.6mm
2.0
0.9
1.2mm
1.3
1.6
1.8mm
2.0
1.2
1.3
1.6mm
2.0
749
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
044
599
079
079 600 053
601
079
602
079
079
606
079
607
608
079
609
079
089
984
610
079
083 318 083
083
317 083
079
614
079 615 053
072
000
053
701
702
053 706
053 704
132
958
132
957
132
956
132
955
132
959
132
960
489
490
053
708
710
U-Grooved
U-Grooved
U-Grooved
U-Grooved
U-Grooved
V-Knurled
V-Knured
V-Knurled
V-Knurled
V-Knurled
V-Knurled
U-Cogged
U-Cogged
U-Cogged
U-Cogged
056
056
056
056
056
056
056
056
056
056
056
056
056
056
056
192
193
193
195
195
192
193
193
195
195
195
193
193
195
195
S-0157-C
OM-180058
Page
19
Page 24
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