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TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Wire Feeder to Power Source Configurations......................................................................A-2
Mounting on Top of the Power Source..........................................................................A-2
Hanging.........................................................................................................................A-2
On the Floor ..................................................................................................................A-2
Control Box Orientation.................................................................................................A-2
Cable Connections...............................................................................................................A-3
Control Cable Connections ...........................................................................................A-3
Control Cable Specifications.........................................................................................A-3
Typical Cabinet Feeder Connection..............................................................................A-3
Control Cable Installation..............................................................................................A-3
Electrode Cable Connections........................................................................................A-3
Electrode Cable Installation ..........................................................................................A-3
Work Cable Connections ..............................................................................................A-4
Wire Drive Gear Ratio (High or Low Speed) ........................................................................A-4
Selecting the Proper Gear Ratio ...................................................................................A-4
Changing the Wire Drive Ratio......................................................................................A-4
DIP Switch Setup .................................................................................................................A-6
Setting DIP Switches in the Control Box.......................................................................A-6
Setting DIP Switches in the Wire Drive.........................................................................A-7
Wire Feed Drive Roll Kits .....................................................................................................A-8
Procedure to Install Drive Rolls and Wire Guides ................................................................A-8
Gun and Cable Assemblies..................................................................................................A-9
Gun Connection Guidelines .................................................................................................A-9
GMAW Shielding Gas ........................................................................................................A-10
Lifting Handle .....................................................................................................................A-10
Optional Features Installation.............................................................................................A-11
Optional Panels for Control Box.........................................................................................A-11
General Panel Installation Guidelines ................................................................................A-11
Operation ............................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
Product Description..............................................................................................................B-1
Recommended Processes and Equipment..........................................................................B-1
Duty Cycle............................................................................................................................B-1
Control Box Operation..........................................................................................................B-1
Control Box Panels - Upper Panel ................................................................................B-1
Control Box Panels - Set Up Controls Description........................................................B-4
Control Box - P.C. Board Adjustments..........................................................................B-4
Control Box - Setting Operating Limits..........................................................................B-5
Control Box - Using Operating Limits............................................................................B-5
Wire Drive Operation............................................................................................................B-6
Wire Drive Settings - External ..............................................................................................B-6
Wire Drive - P.C. Board Adjustments...................................................................................B-7
Wire Reel Loading................................................................................................................B-7
Feeding Electrode and Brake Adjustment............................................................................B-8
Drive Roll Pressure Setting ..................................................................................................B-8
Gas Guard Regulator Setting...............................................................................................B-8
Making a Weld......................................................................................................................B-9
Wire Reel Changing .............................................................................................................B-9
Wire Feed Overload Protection............................................................................................B-9
Component Status Lights...................................................................................................B-10
Status Light States......................................................................................................B-10
Accessories.....................................................................................................Section C
Drive Roll and Guide Tube Kits............................................................................................C-1
Other Accessories................................................................................................................C-2
Maintenance ....................................................................................................Section D
Safety Precautions...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Avoiding Wire Feeding Problems.........................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Procedure for Removing Feedplate from Wire Feeder ........................................................D-1