Specifications

If
field
installation
of
the
WATER
COOLING
KIT
is
required,
follow
the
steps
below:
1.
The Water
Cooling
Kit
mounts
underneath
the
Control
Assembly.
2.
Remove
the
coupling
from
the
torch
end
of
the
water
outlet
pipe
and
from
the
rear
of Con
trol
Assembly,
insert the
pipe
end
of
the
Water
Coolant
Kit
through
the
holes
provided
on
the
Control
Assembly
Supports
opposite
the
shield
ing
gas
solenoid and
fittings.
3.
Two holes
are
provided
inthebottompanelwhich
match
with
the
two
holes
in
the
bottom
of
the
solenoid
valve.
Fasten
the
WATER
COOLING
KIT
to the bottom
panel
with two
10-32
x
1/4
screws.
4.
Remove
the six
prong
plug
(to
which the
gas
solenoid leads are
connected
from the
recep
tacle
in the
rear
panel
of
the
control.
Remove
the
pin
which
holds
the
cover
to the base
of
the
plug.
5.
Loosen the
strain
relief
clamp
screws
and
re
move
the
tape
from
the
leads.
6.
Dress the
twoleads
from
the
water
solenoid
up
to
the
six
prong
plug
and
through
the
strain
re
lief
clamp.~..
7.
Connect
and
solder
separately
one
lead to
plug
terminal
number
3 and the other
lead
to
plug
terminal
number
5.
(Figure
23)
8.
Replace
the
plug
cap
and
pin
removed
in
step
24. 4.
9.
Thread the
coupling
removed
in
step
2-4.
2.
on
to
the
water
inlet
pipe
along
with
the
rest
of
the
fittings.
10.
Connect
a
hose
from
the
WATER
TO
DRAIN
connection
and
connect
the other
end
to
a
water
drain
or
if
a
water
coolant
circulating
system
is
used,
connect
the
water
drain end
to the return
inlet
on
water
coolant
system.
2-5.
115 VOLT AC
RECEPTACLE CONNECTIONS
(Figure
2-4
&
2-5)
Make
up
a
16/3
conductor
cable
long
enough
to
reach
from
the
welding
machine
to
the
control/
feeder.
The
control/feeder
is
supplied
with
nec
essary
female
plug
which
must be
attached
to
one
end
of
the
three
conductor
cable.
Connect
this
cable
to
the
115
volt
ac
receptacle
on
the
welding
machine and
to the
115 volt
ac
receptacle
on
the
rear
panel
of
the control/feeder.
115
volt
ac
for
machine
contactor
Accessory
receptacle
\/r
~~iLIZTFl
Motor

receptacle
~
J
ll5voltac
line
input
L(~UrL
Shielding
gas
connection
\
Water
coolant
connection
(Optional)
AA-056
132-5A
Figure
2-5. Rear
Panel
Of
Control
Assembly
2-6. WELD
CONTACTOR
CONTROL CONNECTIONS
(Fig
ure
2-4)
Make
up
a
16/2
conductor
cable
the
same
length
as
the 115
volt
ac
three conductor
cord.
The
control/feeder
is
supplied
with the
nec
essary
male
plug
which
must
be
attached
to
one
end of
the two
conductor
cord.
Connect
this cable
to the
CONTACTOR
CONTROL
receptacle
on
the
welding
machine
and
to the
female
receptacle
on
the
rear
panel
of
the
control/feeder.
TABLE 2-1.
Cable
Size
For Gas
Metal-Arc
(MIG)
Welding
AMPERES
MAX.
CABLE
LENGTH
CABLE SIZE
200
300
400
500
600
15
Feet
15
Feet
15 Feet
15
Feet
15
Feet
No.
1
No.
2/0
No.
3/0
No.
4/0
No.
22/0
If
longer
cable
is
required,
double
the size
of
cable
listed.
2-7.
POWER
SOURCE
WELD
CONNECTIONS
(Figure
2-4
&
2-6)
Make
a
length
of
welding
cable
of
suitable
size
(See
Table
21
for
welding
cable
size)
long enough
to
reach
from
the
welding
machine
to
the electrode
welding
cable
connector
assembly
on
the
control/
feeder.
Connect
a
lug
of
suitable current
rating
having
91/2 inch
diameter
hole
to
one
end of
this cable
and
a
large
enough
diameter
hole
lug
on
the
other
end
of
this
cable
to
fit
the POSITIVE
(+)
secondary
terminal
on
the
welding
machine.
This
connection
is
for
reverse
polarity
welding.
Connect
the electrode
cable
to
the POSITIVE
secondary
terminal
on
the
welding
machine.
Con
nect
the
other
end to the
ELECTRODE
WELDING
CABLE
CONNECTOR
ASSEMBLY
on
the control/
feeder,
but
do not
tighten
as
the
electrode
cable
from
the
Gun
or
Torchwill also be
connected
to this
terminal.
Make
up
a
welding
cable
of
proper
size
and
of
suitable
length
(see
Table
21)
to reach
from
the
welding
machine
to
the
workpiece.
Attach to
one
end of
this
cable
a
suitable diameter hole
lug
and
connect
to
the NEGATIVE
(-)
terminal
on
the
welding
machine.
Attach
to
the
other end
of
the
cable
a
C~
type
clamp
and make
a
good
solid
connection
to
the
workpiece.
AA-056 132-6
/
Electrode
welding
cable
connector
assembly
Figure
2-6.
Power
Source
Connection
OM-1234
Page
3