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DMG EFD Remote control circuit common. EF E 0 to +10 volts dc output signal from wire feeder to power source with respect to socket D. H Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts. F Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes. *The remaining pins are not used. 4-4. Gun Recommendation Table Process Gun GMAW – Hard or Cored Wires Roughneck C-Series Guns: 300, 400, 500, And 600 Amp. FCAW – Self-Shielding Wires FC-1260 Or FC-1150 4-5. Wire Type, Size, And Feed Speed Capability Table Motor Speed Wire Type Wire Size Feed Speed Capability Standard All .023 To 5/64 in (0.6 To 2 mm) 50 To 780 ipm (1.3 To 19.8 mpm) Standard All 3/32 To 7/64 in (2.4 To 2.8 mm) 50 To 700 ipm (1.3 To 17.8 mpm) Standard All 1/8 in (3.2 mm) 50 To 300 ipm (1.3 To 7.6 mpm) Optional High Speed All .023 To 5/64 in (0.6 To 2 mm) 90 To 1440 ipm (2.3 To 36.6 mpm) OM-1500-1 Page 13 OM-1500-1 Page 14 4-6. Installing And Threading Welding Wire Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 802 954 / S-0627-A Tools Needed: Be sure that outlet cable has proper size liner for the welding wire size. When installing gun, position liner extending from outlet wire guide as close as possible to drive rolls without touching. Install gun. Lay gun cable out straight. Cut off end of wire. Push wire through guides up to drive rolls; continue to hold wire. Press Jog button to feed wire out gun. For soft wire or small diameter stainless steel wire, reduce drive roll pressure on the rear roll to half that of the front rolls. To adjust drive roll pressure, hold nozzle about 2 in (51 mm) from nonconductive surface and press gun trigger to feed wire against surface. Tighten knob so wire does not slip. Do not overtighten. If contact tip is completely blocked, wire should slip at the feeder (see pressure adjustment above).Cut wire off. Close cover. NONCONDUCTIVE SURFACE NONCONDUCTIVE SURFACE No Wire Slip Wire Slips Install wire spool. Adjust tension nut so wire is taut when wire feed stops. Install wire guides and anti-wear guide. Install drive rolls. 3/16, 5/64 in 15/16, 3/8 in Pressure Adjust Front Rolls Pressure Indicator Pressure Scale Adjust Rear Rolls Drive Rolls End Of Liner Gun Cable 4-7. Setting Internal DIP Switches 1 . When DIP switch positions are changed, the unit must be turned Off and then On again in order for the new settings to be active. DIP switches are only read on power up. 802 808 2 1 2 3 4 5 6 7 8O N In the DIP switch S1 illustrations, the elevated slider on each switch is show in white. For example, the switches above are all in the Off position. Position Settings And Results For DIP Switch S1 On = Front panel display shows weld amperage during welding. Off = Front panel display Off = Front panel display 3 Off, 4 On = Range limit 3 On, 4 On = Range limit shows wire feed speed shows wire feed speed in on voltage and wire feed on voltage and wire feed during welding. inches per minute. speed set at ±10%. speed set at ±20%. 2 2 On = Front panel display shows wire feed speed in meters per minute. 34 34 * 3 Off, 4 Off = Range limiting disabled (locks Off). 34 34 3 On, 4 Off = Range limit on voltage and wire feed speed set at ±5%. On = Front panel display holds weld parameters for 5 seconds following trigger release. Off = Front panel display returns to preset upon trigger release. 6 6 7 8 On = Current detect override. For welding power sources that don’t provide current feedback through the 14-pin receptacle. 7 8 Off = Current must be detected to go from run-in to welding condition. 78 7 Off, 8 Off = Normal 7 On, 8 Off = Reserved speed motor (50–780 for future use. inches per minute) 78 7 Off, 8 On = High speed 7 On, 8 On = Reserved motor (90–1440 inches for future use. per minute) 1 DIP Switch S1 2 DIP Switch S4 (Not For Customer Use) DIP switch S1 allows the user to make a num ber of choices affecting unit operation. . Selecting Weld Amperage Or Wire Feed Speed Display (S1-1) If the front panel DIP is set in the display amps position, the lower display (see Section 5-6) shows amperage while the unit is welding at an amperage value above 25 Amps and the current detect override is in the Off position. If the amperage display position is not used, the lower display shows wire speed. . Selecting Wire Feed Speed Value (S1-2) The unit displays wire speed in units of inches per minute (IPM) if the English/Metric wire feed display DIP is in the English position. The unit displays wire speed in meters per minute (MPM) if the DIP is in the metric position. . Adjusting Range Limits (S1-3 & 4) The lock feature provides a means of regulat ing unit settings, but still allows some level of adjustment through the Adjust control. When a lock position is used, the lock applies to all programs. Two DIP switches are dedicated to locking unit settings. Four possible combinations of the two DIP switches provide the following settings: Locks Off, Locks On ±5%, Locks On ±10%, and finally Locks On ±20%. If the wire speed is at 300 IPM...