Miller Electric DWF3 User Manual
August 2000 Form: OM-179 078
Effective With Serial No. KG041900
OWNER’S
MANUAL
cyclomatic
Model DWF–3 Cold Wire Feeder System
Automatic Control For Supplying Filler Wire Into The Weld
GTAW And PAW
Stepper Motor For Accurate, Repeatable Feed Rates
120/240 Volts AC Input Power To Control Unit
Overload Protection
Automatic Wire Retract At End Of Weld Cycle
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
cover 5/94 PRINTED IN USA
1996 MILLER Electric Mfg. Co.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821
From Miller to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. T o obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.
ARC WELDING SAFETY PRECAUTIONS
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, and
all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry , hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
7. When making input connections, attach proper grounding
conductor first – double-check connections.
8. Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
9. Turn off all equipment when not in use.
10. Do not use worn, damaged, undersized, or poorly spliced cables.
11. Do not drape cables over your body.
12. If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
13. Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
14. Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
15. Wear a safety harness if working above floor level.
16. Keep all panels and covers securely in place.
17. Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Noise from some processes
can damage hearing. Chipping, grinding, and welds
cooling throw off pieces of metal or slag.
NOISE
1. Use approved ear plugs or ear muffs if noise level is high.
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
2. Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
ARC RAYS
2. Wear a welding helmet fitted with a proper shade of filter to
protect your face and eyes when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
3. Wear approved safety glasses with side shields.
4. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing a n air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
4. Never drape a welding torch over a gas cylinder .
5. Never allow a welding electrode to touch any cylinder.
6. Never weld on a pressurized cylinder – explosion will result.
7. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
8. Turn face away from valve outlet when opening cylinder valve.
9. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
10. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
sr1.1.1 2/94
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly off
from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby .
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to A WS F4.1 (see
Safety Standards).
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine and let it cool off before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
SPARKS can cause BATTERY
GASES TO EXPLODE; BATTERY
ACID can burn eyes and skin.
Batteries contain acid and generate explosive
gases.
ENGINES can be hazardous.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
3. Do not overfill tank – allow room for fuel to expand.
4. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative ( –) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
It is best to check coolant level when engine is cold
to avoid scalding.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society ,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFP A Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
sr1.1.1 2/94
1. If the engine is warm and checking is needed, follow steps 2
and 3.
2. Wear safety glasses and gloves and put a rag over cap.
3. Turn cap slightly and let pressure escape slowly before
completely removing cap.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
! IMPORTANT !
THIS MANUAL HAS BEEN DESIGNED FOR EXPERIENCED WELDING EQUIPMENT OPERATORS AND
MUST BE READ COMPLETELY BEFORE USING THIS EQUIPMENT. IF YOU LACK EXPERIENCE OR
ARE UNFAMILIAR WITH THE PRACTICES AND SAFE OPERATION OF WELDING EQUIPMENT,
PLEASE CONSULT YOUR FOREMAN. DO NOT ATTEMPT TO INSTALL, OPERATE, OR PERFORM
MAINTENANCE ON THIS EQUIPMENT UNLESS YOU ARE QUALIFIED AND HAVE READ AND
UNDERSTAND THIS MANUAL. IF IN DOUBT ABOUT INSTALLING OR OPERATING THIS EQUIPMENT,
CONTACT YOUR DISTRIBUTOR OR THE CUSTOMER SERVICE DEPARTMENT.
DEFINITIONS
NOTE CAUTION WARNING DANGER
Throughout this manual, NOTE, CAUTION, WARNING and DANGER are inserted to call attention to
particular information. The methods used to identity these highlights and the purpose for which each is used,
are as follows:
NOTE
OPERATIONAL, PROCEDURAL, AND BACKGROUND INFORMATION WHICH AIDS THE OPERATOR IN
THE USE OF THE MACHINE, HELPS THE SERVICEMAN IN THE PERFORMANCE OF MAINTENANCE,
AND PREVENTS DAMAGE TO THE EQUIPMENT.
CAUTION
AN OPERATIONAL PROCEDURE WHICH, IF NOT FOLLOWED, MAY CAUSE MINOR INJURY TO THE
OPERATOR, SERVICE PERSONNEL AND/OR BYSTANDERS.
WARNING
AN OPERATIONAL PROCEDURE WHICH, IF NOT FOLLOWED, MAY CAUSE SEVERE INJURY TO THE
OPERATOR, SERVICE PERSONNEL, OR OTHERS IN THE OPERATING AREA.
DANGER
AN OPERATIONAL PROCEDURE WHICH, IF NOT FOLLOWED, WILL CAUSE SEVERE INJURY OR
EVEN DEATH TO THE OPERATOR, SERVICE PERSONNEL OR BYSTANDERS.
EMF INFORMATION
NOTE
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us t o draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
TABLE OF CONTENTS
DESCRIPTION
1.1 INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 CONTROL UNIT 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 WIRE DRIVE UNIT 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 WIRE GUIDE ASSEMBLY 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mod10.1 4/93
INSTALLATION
2.1 GENERAL SET–UP 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 CONTROL UNIT LOCATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 WIRE DRIVE UNIT MOUNTING 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 WIRE GUIDE MOUNTING 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 CONDUIT LENGTH ADJUSTMENT 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 REMOTE CONTROLS 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 CHANGING RETRACT DISTANCE 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION
3.1 PRECAUTIONS 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 CONTROL DESCRIPTION – DWF–3 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 SEQUENCE OF OPERATION 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 REMOTE SIGNALS 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR
4.1 MAINTENANCE REQUIREMENTS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 GENERAL PRECAUTIONS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 CONTROL UNIT CALIBRATION 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 DRIVE UNIT ASSEMBLY 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 TROUBLESHOOTING 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DESCRIPTION
5.1 SPEED CONTROL CIRCUITS 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 DELAY TIMER CIRCUITS 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 DIGITAL DISPLAY CIRCUIT 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 MOTOR POWER SUPPLY CIRCUIT 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 DESCRIPTION
1.1 INTRODUCTION
Cold wire feed systems are designed for accurate application of filler wire into the weld or braze area. The
DWF–3 is designed to be used for GTAW and PA W processes. The Digital Wire Feeder System is made up of
a positive feeding wire drive with a zero backlash 3–axis wire manipulator. This combination of components
produces exceptionally good wire feeding characteristics. Systems will accommodate wire sizes from .020 in
diameter (.50 mm) to .094 in diameter (2.39 mm) and feed at an adjustable rate, continuously variable from 0
to 300 inches per minute. A standard DWF–3 system is shown in Figure 1.1.
1.2 CONTROL UNIT
The control unit uses solid state circuitry in its motor supply and control circuits and operates from a 115/230
VAC, 50/60 Hz line supply. Provisions have been made for forward or reverse jog to allow easy
pre–positioning of the filler wire. Start of wire feed and control of speed may be accomplished both manually
from the front panel or remotely through the interface connector located on the rear panel. The speed at which
the wire will feed is pre–set through use of the ”PUSH TO SET” function on the front panel and can be
controlled within 0.10 inch per minute increments. A digital readout of wire speed is provided. Start delay and
stop delay timers are also provided for cycle control. Timers can be pre–set within 0.10 second intervals from
0 to 9.9 seconds.
1.3 WIRE DRIVE UNIT
The wire drive unit uses urethane rollers to grip the wire and feed it in either direction depending on the signals
from the control unit. These rollers eliminate the need to change rollers when changing wire sizes from .020 in
(.50 mm) diameter through .062 in (1.57 mm) diameter wire. Special rollers are required for .094 in (2.39 mm)
diameter wire. All wire can be loaded into the drive while it is operating. There is no need to hand–feed the wire
through the mechanism before operating. Inlet and exit guides are provided with the wire drive. One inlet guide
covers the entire range of wire sizes from .020 in diameter (.50 mm) to .094 in (2.39 mm) diameter. Three exit
guides cover the range of wire diameters. Two of the exit guides are for the .020 in through .062 in range. The
third is for the .094 in wire. The guides are stored inside the drive housing. If a drive for .020 in – .062 in wire is
ordered, then two exit and one inlet guide will be supplied. If a drive for .094 in wire is ordered, then one exit and
one inlet guide will be supplied.
1.4 WIRE GUIDE ASSEMBLY
The wire guide assembly which is used with the DWF–3 wire drive unit consists of a guide mechanism,
conduit, liners, and tip. The guide mechanism is constructed to allow full position adjustment for vertical, cross
seam, feed angle and distance from the electrode. Tips and liners can be changed to suit the wire size being
used (see information listed in Table 1.1) Standard length of the conduit supplied with the system is 36 in
(914.4 mm). The length may be shortened by following steps 2.5A through 2.5D in the installation section.
TABLE 1.1 WIRE GUIDE DETAILS
WIRE SIZE ROLLER EXIT GUIDE LINER GUIDE TIP
.020 in (.50 mm) 179 170 179 173 179 184 –
.030 in (.76 mm) 179 170 179 173 179 184 –
.035 in (.89 mm) 179 170 179 173 179 184 –
.045 in (1.1 mm) 179 170 179 173 179 184 –
.062 in (1.5 mm) 179 170 – 179 185 –
OM-179 078 1-1
SECTION 1 DESCRIPTION
You may also order a combination of the wire guide mechanism, tip, conduit assembly, and conduit liner
together as follows:
.020 – .062 in dia. 179 165*
*This includes all tips necessary for operation of .020 – .062 in dia. wire in one package.
Figure 1.1, DIGITAL WIRE FEED SYSTEM
OM-179 078 1-2
SECTION 2 INSTALLATION
2.1 GENERAL SET–UP
A standard DWF–3 system is illustrated in Figure 2.1 with the necessary interconnections shown for a typical
installation. The parts are listed below:
DWF–3 (.020 – .062)
CONTROL UNIT 179 166
WIRE DRIVE UNIT 179 164
WIRE GUIDE ASSEMBLY 179 165
2.2 CONTROL UNIT LOCATION
The control unit should be placed in a location which provides easy access to the controls and proper air
ventilation for cooling. Adequate ventilation is provided by maintaining a minimum of 5 in (127 mm) of
unrestricted space between the control unit sides and rear and the nearest obstruction. The location should be
selected to minimize any dust, dirt, moisture or corrosive vapors the control unit could be subjected to. Control
unit outline dimensions are given in Figure 2.2.
CAUTION
THE CONTROL UNIT CAN OPERATE ON EITHER 100/120 VOLTS OR 208/230 VOL TS AC, 50 OR 60 HZ.
BE SURE TO SELECT THE PROPER INPUT VOLTAGE ON THE REAR PANEL BEFORE CONNECTING
TO POWER.
2.3 WIRE DRIVE UNIT MOUNTING
Figure 2.3 is an outline and a mounting dimension guide. The drive unit may be mounted using the inlet guide
surface or the bottom surface (opposite the adjusting knob) through use of the existing tapped holes in the
housing. The wire drive exit guide has a 7/16 – 20 UNF external thread for mating with the supplied wire guide
conduit for a DWF–3 system.
CAUTION
IN APPLICATIONS WHERE HIGH FREQUENCY OR CAPACITIVE DISCHARGE START IS USED THE
DRIVE HOUSING SHOULD BE GROUNDED TO THE SAME POTENTIAL AS THE WORKPIECE. THIS
WILL PREVENT POSSIBLE DAMAGE TO THE WIRE FEED DRIVE,CAUSED BY ARCING. GROUNDING
CAN BE ACCOMPLISHED THROUGH THE UNUSED THREADED MOUNTING HOLES IN THE DRIVE
HOUSING.
OM-179 078 2-1
SECTION 2 INSTALLATION
Figure 2.1, DIGITAL WIRE FEED INSTALLATION
OM-179 078 2-2
SECTION 2 INSTALLATION
Figure 2.2, CONTROL UNIT OUTLINE
OM-179 078 2-3
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