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TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ...............................................................................................................A-2
Mounting the Wire Drive Unit ...............................................................................................A-2
Boom Mounting of Wire Drive .......................................................................................A-2
Electrode Routing..........................................................................................................A-2
Mounting the Control Box and Receptacle Configuration ....................................................A-2
Separating the Control Box from the Wire Drive (Bench Model Only) ..........................A-2
Mounting the Control Box (Boom or Separated Bench Models) ...................................A-3
Determining Receptacle Configuration .........................................................................A-3
Mounting on Power Source...........................................................................................A-3
Control Cable .......................................................................................................................A-3
Control Cable Connections ...........................................................................................A-3
Control Cable Specifications.........................................................................................A-4
Available Cable Assemblies..........................................................................................A-4
Electrode Cable Connections........................................................................................A-4
Work Cable Connections ..............................................................................................A-5
Wire Drive Gear Ratio (High or Low Speed) ........................................................................A-5
Selecting the Proper Gear Ratio ...................................................................................A-5
Changing the Wire Drive Ratio......................................................................................A-5
DIP Switch Setup .................................................................................................................A-7
Setting DIP Switches in the Control Box and Wire Drive ..............................A-7 thru A-10
Wire Feed Drive Roll Kits ...................................................................................................A-11
Procedure to Install Drive Rolls and Wire Guides ..............................................................A-11
Gun and Cable Assemblies with Standard Connection......................................................A-11
Gun and Cable Assemblies with Fast-Mate Connection....................................................A-11
General Gun Connection Guidelines..................................................................................A-12
GMAW Shielding Gas ........................................................................................................A-13
Gas Guard Regulator..................................................................................................A-13
Wire Spindle Placement.....................................................................................................A-13
Water Connections (For Water Cooled Guns) ...................................................................A-13
Wire Feed Shut Down Circuit (Optional) ............................................................................A-13
Optional Features Installation.............................................................................................A-14
Optional Panels for Control Box.........................................................................................A-14
General Panel Installation Guidelines ................................................................................A-14
Boom and Bench Conversions...........................................................................................A-14
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
Operation with Previous Software Versions.........................................................................B-6
Wire Drive Operation............................................................................................................B-6
2 Step/4 Step Switch Operation....................................................................................B-6
Cold Feed/Gas Purge Switch........................................................................................B-6
Wire Drive - PC Board Adjustments .....................................................................................B-7
Wire Reel Loading................................................................................................................B-7
Feeding Electrode and Brake Adjustment............................................................................B-9
Drive Roll Pressure Setting ..................................................................................................B-9
Procedure for Setting Angle of Feedplate ............................................................................B-9
Gas Guard Regulator Setting...............................................................................................B-9
Making a Weld....................................................................................................................B-10
Wire Reel Changing ...........................................................................................................B-10
Wire Feed Overload Protection..........................................................................................B-10
Component Status Lights...................................................................................................B-11
Status Light States......................................................................................................B-11
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
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