Download Miller Electric GA-16C1 Specifications
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MiOØrfi~ April Form: 1993 OM-157 745 Effective With Serial No. KD398640 ~i4 #~41uI14Ft~4S4IV1 ~a - p I I ~ ~.w OWNERS MANUAL Gold SealTM Model 5000 CV/DC Welding Power Source/Wire Feeder For FCAW Rated Welding Or GMAW Welding Output Of 70 Uses 115 VAC Amperes With Optional Gas At 16 Volts DC, 20% Single-Phase Input Valve Duty Cycle Power Motor Overload Protection Basic Model Includes Gun, Standard Model Adds Gas Valve, Deluxe Model Adds Gas Regulator/Flowmeter Read and follow these instructions and all safety blocks Have only trained install, operate, or and 8/92 ST.161 158 Give this manual to the operator. qualified persons service this unit. Call your distributor if you do not understand the directions. cover U carefully. For or: help, call your distributor MILLER ELECTRIC Mfg. Co., 1079, Appleton, WI 54912 P.O. Box 414-734-9821 PRINTED IN USA - F U J MILLERS TRUE BLUETM LIMITED WARRANTY EffectIve (Equipment This limited werrenty a January 1, 1992 preface of serial number supersedes sit previous MILLER warrentlas end to the terms end conditions WARRANTYSubject Mlg. Co., Appleton, Wioconain, LIMITED with werrents to its is eaclunive with no other below, MILLER Electric retell purcheser thet original new MILLER equipment sold elfer the effective dete of this limited werrenty is free of de tects in meteriel end workmanship et the time it is shipped by MILLER. THIS WAR RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR or gusrentees Acceeeory Kite * Replecement Perle True BtuenM Iteme furnished 1. newer) * MILLERS IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT NESS. KC or Limited warrenflea espreseed Werrenty shell werrenty periods listed below, MILLER will repeir or replece eny provide instructions on the werrenty cleim procedures end to be 3. on the dete thet the equipment wee delivered to the originel retell Originel en contect tips, culling nozzles, contectore hen been modified by eny perty other then MILLER. or equip improperly inetelled, improperly opereted or mIsused induetry etenderde, or equipment which hee not hed reeeonebte based upon purcheser, equipment which hoe been end neceeeery meintenence, or outside of the for the epeciticetione used for operetlon equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER CIAtJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EOUIPMENT. mein power rectifiers Perts end Lebor 3 Yeers 2. es engines or by the menufeclurers werrenty, If ment thet hee been 3 Yeers Lebor S Yeers Perts covered releye. Equipment thet end ere es follows: t. ere Coneumeble components; euch 2. MILLER shell honor werrenty ctelme on werrented equipment listed below in the event of such e teilure within the werrenty time periods. All werrenty time periods stert to: eny. wer rented perle or components thet tell due to such defects in meteriel or workmanship. MILLER must be notified in writing within thirty (30) deys of such detect or teiture, et which time MILLER will followed. epply Implied. by MILLER, but menufectured by others, such trede ecceeeoriee. These items Within the not or In the event of e werrenty claim covered by this werrenty. the eecluslve remedies be, et MILLERS option: II) repeir; or 12) replecement; or, where euthorlzed In writing by MILLER in eppropriete ceees, )3) the reesoneble cost of repelr or replece ment at en euthorized MILLER service stetlon; or (4) peyment of orcredlt for the pur chase price (less reesonebte deprecietion besed upon ectuel use) upon return of the goode et customers risk end espenee. MILLERS option of repeir or reptecement will be FOB., Fectory at Appleton, Wisconsin, or FOB. et e MILLER euthorlzed ser vice facility es determined by MILLER. Therefore no compensetion or reImburse ment for transportation costs of eny kind wilt be ellowed. Treneformer/Rectilier Power Sources Plesme Arc * Cutting shell Power Sources Semi-Autometic end Autometic Wire Feeders Robots Perte end Lebor 2 Yeers 3. Engine Driven Welding Generet ore )NOTE: Engines em werrented eeperetely by 1 Yeer 4. the engine menufecturer.) TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECt SPECIAL, INCIDENTAL OR CONSEOUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT). WHETHER BASED ON CON TRACT, TORT OR ANY OTHER LEGAL THEORY. Perte end Lebor Motor Driven Guns * Process Controllers Water Coolent Systems HF Unite * ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR Grids Spot RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EOUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MtLLER. Welders Loed Benko * SDX Trenetormern Running Geer/Treilere Options * * Field (NOTE: Field options ere covered under True BIaenM for the remeining werrenty period of the product they ere inatelled in, or for e minimum of whichever in greeter.) one yeer S. 6 Months 6. 90 Deye Some otetee in the U.S.A. do not allow Ilmitetions of how lesto, cific Bell eries Perle end Lebor MIG Gune/TIG Torches Culling Pleeme * Remote Controls long en implIed werrenty the eaclusion of incidentel. indirect. opeciel or consequentlel demeges, so or eaciusion may not apply to you. This werrenty provides spe legal rights, end other In Canada, legislation in or remedies other than rights some as may be available, but may vary from state to state. provinces provides for certain additional warranties staled herein. and to the entent that they may not be waived, the limitations and eaclusione eat out abova may not apply. ThIs Limited Warranty provides specific legal rights, and other rights may be available, but may vary 1mm province to province. Torches * or the ebove limitation 4> al- RECEIVING-HANDLING unpack)ng equipment, ChBCk carton for any damage that may haVB occurred dUr)ng shipment. File any C)aimS for )oss or damage delivering carrier, Assistance for filing or setthng c)aims may be obta)ned from distributor and/or equipment manufacturers Transportation Department. Before with the When requesting Use the or following information about this equipment, always provide Mode) Designation and Serial spaces to record Model Designation and Serial or Style Number of your unit. or Style Number. The information is located on the rating label nameplate. Model _________ Serial or Style No. Date of Purchase miller 5/92 ARC WELDING SAFETY PRECAUTIONS Read all all Obey safety messages throughout this manual. safety messages Learn the 1 meaning to avoid injury. of WARNING and CAUTION. 2 1 Safety 2 SignalWord 2 \ Alert WARNING A~ WARNING I a CAUTION 3 ______________ ELECTRIC SHOCK ~ can kill Do not touch live electrical parts. Disconnect installing or input power servicing. 1…~I. h J~j before ~ or MOVING PARTS Keep all panels operating. and covers closed possible death happen. can means possible minor injury or equipment damage can happen. Keep away tram moving parts. when means injury CAUTION I Injure. can serious Symbol I / 3 Statement Of Hazard And Result 4 Safety 5 Instructions To Avoid Hazard READ SAFETY BLOCKS at start of Section 3-1 before proceeding. V 6 I 5 Hazard 6 Safety Banner Read 7 ~ Turn Off switch when using high frequency. NOTE Special instructions for best ation not related to safety. WARNING A~ blocks for each sym. bol shown. _____ NOTE safety Symbol (If Available) ARC WELDING can oper 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. 5. 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 3. Insulate dry, hole-free yourself insulating gloves and body protection. ground using dry insulating Disconnect input power servicing this equipment. /~p~ ~2 - or stop engine before installing install and Manual and national, state, and local codes. 6. Turn oft all 7. Do not cables. ground equipment use worn, this equipment according when not in Do not wrap cables around your body. 9. Ground the electrical workpiece good to a or poorly spliced (earth) ground. 10. Do not touch electrode while in contact with the work circuit. 11. Use only well-maintained equipment. damaged parts at once. 12. Wear a safety harness to to its use. damaged, undersized, 8. from work and mats or covers. 4. Properly Owners Repair or (ground) replace prevent falling if working above floor level. or 13. Keep all ARC RAYS can burn eyes and skin; NOISE can damage hearing. 1. Wear a Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage 2. Safety Standards) to protect your face and eyes when welding or watching. Wear approved safety glasses. Side shields recommended. 3. Use hearing. panels welding and covers securely helmet fitted with a in place. proper shade of filter (see ANSI Z49.1 listed in and 4. 5. protective screens or barriers to protect others from flash glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. Use approved ear plugs or ear muffs if noise level is high. FUMES AND GASES 5. be hazardous can Welding produces fumes and gases. Breathing these fumes and gases 6. 1. 2. 3. 4. Safety Data Sheets (MSDSs) and the instruction for metals, consumables, coatings, Read the Material 7. weld area, the Watch for fire, and Be and others from (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers, Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas, can FLYING SPARKS AND HOT METAL cool, they and cause throw off CYLINDERS fire keep welding on a fire on a extinguisher nearby. ceiling, floor, bulkhead, partition . Connect work cable to the work as close to the welding area as practical to prevent welding currentfrom traveling long, possibly Do not 11. on closed containers such paths and causing electric use welder to thaw frozen tip when not in Wearoil-free Wear tanks or drums. shock and fire hazards. or cut off wire at welding use. protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and 1. as pipes. Remove stick electrode from holder contact can or the hidden side. approved face shield or a cap. safety goggles. Side shields recommended. grinding can is well ventilated, and if necessary, while 8. injury, Chipping spraying Do not weld 10. Remove all flammables within 35 ft cause or with vapors to 7. 9. strike flammable material. Do not weld where that can cause and hot metal. 2. flying sparks aware unknown . flying sparks 3. 4. area 6. yourself can react wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. fire, Protect the on coated metals, such as galvanized, lead, or plated steel, unless the coating is removed from the 5. or sure Do not weld explosion. fire can cause degreasing, cleaning, near The heat and rays of the arc toxic and irritating gases. Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode orwelding wire to metal objects can cause sparks, overheating, or WELDING while or used for air is safe. Do not weld in locations cadmium and cleaners. 1. an operations. form highly Keep your head out of the fumes. Do not breath the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. manufacturers only if it is well ventilated, air-supplied respirator. Shielding gases can displace air causing injury or death. Be confined space a breathing be hazardous to your health. can Work in wearing welding to your health. can 2. metal. As welds flying Wear proper body protection to protect skin. slag. explode if 3. damaged. from any Keep cylinders away welding other electrical or circuits. 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. 4. 5. 6. 1. Protect 2. cylinders in them to a stationary support prevent falling or tipping. secure an or excessive 7. upright position by chaining equipment cylinder rack to 8. gas cylinders mechanical shocks, and arcs. Install and from heat, compressed a welding electrode to touch any cylinder. only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is Never allow Use in use or connected for use. Read and follow instructions associated equipment, compressed gas cylinders, publication P-i listed in Safety on and CGA Standards. PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting, ANSI Standard Z49.1, Safetyand Health Standards, OSHA 29 CFR 1910, from Recommended Safe Practices for the Society from American Welding Society, Superintendent of Documents, 550 N.W. LeJeune Rd, Miami FL 33126 U.S. Government Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, Standard AWS F4.1, from American Welding Society, Handling of Compressed Gases in American 20402. Welding 550 N.W. LeJeune Rd, Miami, FL 33126 National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Safe Printing Office, Washington, D.C. Cylinders, CGA Pamphlet P-i, from Batterymarch Park, Quincy, Compressed Gas Association, MA 02269. 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87. 1 ,from American National Standards Institute, 1430 Broadway, Cutting New York, NY 10018. And Welding Processes, NFPA Standard 51 B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. TABLE OF CONTENTS SPECIFICATIONS SECTION 1 1-1. Volt-Ampere Curve And Duty Cycle Chart 1 SECTION 2INSTALLATION 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. Installing Work Clamp Polarity For Wire Type Installing Welding Gun Connecting Input Power Threading And Feeding Welding Installing Gas Supply 2 Gun 2 3 3 Wire . SECTION 3OPERATION 3 5 6 SECTION 4- MAINTENANCE & TROUBLESHOOTING 4-1. Overload Protection 4-2. Drive 4-3. Gun Maintenance 4-4. Troubleshooting 7 Assembly Maintenance 10 SECTION 5 ELECTRICAL DIAGRAMS SECTION 6 PARTS LIST Figure Figure Figure 6-1. Main 6-2. Drive Assembly Assembly, 6-3. GA-i 6C1 Gun 8 9 11 13 Wire 15 16 OM.1 57 745 4/93 SECTION 1 SPECIFICATIONS Table 1-1. Welding Power Source Description Specifications Type Of Constant Output Rated Weld Output Type Of Input 70 At Rated Output Welding Voltage 29 Volts DC 24 Volts DC At Gun (FCAW) Flux Cored Arc Processes Speed Range 60 Hz; At 115 Volts AC 2.2 kVN2 kW Open-Circuit Voltage Control Circuit 22 To 286 At No Load ipm (0.6 (0.58 Overall Dimensions Length: 16-1/2 in Weight Net: 53 lb Range And Gas Metal Arc To 7.3 .023 To .035 in Wire Diameter (CV/DC) 15 A KVA/KW Used At Rated Output Max. Current Amperes, 16 Volts DC, 20% Duty Cycle Single-Phase; Power Input Amperes Voltage/Direct To 0.89 mm) (419 mm); Width: 9-1/2 (24 kg); Ship: Welding (GMAW) mpm) 65 lb in (241 mm); Height: 17 in (432 mm) (29 kg) Welding Gun Rated Output (Air Cooled) 160 Cable Length 10 ft 1-1. Curve And Volt-Ampere Amperes At 60% Duty Cycle Using CO2 Shielding Gas (3 m) Duty Cycle Chart CAUTION a U SING GUN BEYOND DUTY CYCLE RATING Do not use beyond gun Use gun at 30% duty cycle when using mixed can using CO2 rated amperage when damage gun. shiel ding gas. shielding gas. ~arn8.1 10/91 The volt-ampere curves show the minimum and maximum voltage 30 and amperage output capabilities of the welding power source. 25 20 Curves of other settings fall be tween the curves shown. 15 Duty cycle is how long the unit can operate within a ten minute period g without 5 causing overheating or damage. 0 This unit is rated at 20% duty cycle allowing welding 2 minutes out of every 10 minutes. DC AMPERES This gun is rated at 60% duty cycle when using CO2 shielding gas and 30% when using mixed shielding gas. I0 5 20 30 25 DUTY Figure OM-157 745 Page 1 1-1. CYCt.E 40 50 60 70 80 90 00 ssbl.1 10/91 /sbl.3 10/91 SB-157 ~ Volt-Ampere Curve And Duty Cycle Chart 146/SB.121 475 SECTION 2 2-1. Work Installing INSTALLATION Clamp 1 Insulator 2 Bolt 3 Smaller Hole 4 Work Clamp Tabs Bend tabs around work cable. 5 Work Cable From Unit 6 Nut Tools Needed: ~ 3/8, 7/16 in Ret. ST-025 190-C Figure 2-2. Gun Polarity For Wire 2-1. Installing Work Clamp Type WARNING a ELECTRIC SHOCK can Do not touch live electrical Turn Oft welding kill. parts. power source, and disconnect input power before inspecting or installing. SwOrnl.1 2/93 1 ~ For Flux Cored Wires (FCAW Processi J ~ L STRAIGHT POLARITY ~ I REVERSE POLARITY ~{~ I For Solid Steel Or Aluminum L DCEN Polarity Changeover Polarity Jumper Links Always wire mended Wires S.~.P 1 2 IGMAWI Processi read and follow manufacturers Label welding recom polarity. Close door. OCEP GUN POLARITY CHANGEOVER S-116 599-Cl 2 Tools Needed: C~~~JzztC C I )1 ~) I 1 I _______ 1 1 1 1 - 3/8 in Ref. ST-159 619-A Figure 2-2. Gun Polarity Connections OM-157 745 Page 2 Installing Welding 2-3. Gun 1 Gun 2 Drive 3 Gun End Loosen Securing Nut Assembly bottoms securing nut. Insert end panel opening until it against drive assembly. Tighten nut. through 4 front Gun Trigger Insert leads, grommet leads to on one Leads at front matching a time, through panel. Connect leads in unit. Close door. Tools Needed: ~ 5/l6in Ref. ST.159 619-A/ Ret. ST-159 216 Figure 2-4. Connecting Input 2-3. Gun Connections Power Connect unitto a properly grounded 115 VAC receptacle of a 20 ampere individual branch circuit protected bytime-delay or circuit breakers. Select an extension cord of 12 AWG for up to 75 ft (23 m) or 10 AWG for up to 140 ft (46 m). fuses 2-5. Threading a And Feeding Welding Wire WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. welding wire, drive rolls, drive assembly, and all metal parts touching the welding wire are electrically live when welding or feeding wire using gun trigger. S The WELDING WIRE wounds. Do not press gun can trigger cause S so. ~ .~_ - ~ Donotpointguntowardanypartofthebody,other people, or any metal when threading welding wire. can burn skin. can Allow gun to cool before C YLINDERS puncture until instructed to do HOT SURFACES touching. explode Keep cylinders away from if damaged. welding and other electrical circuits. Never touch cylinder with Always secure cylinder other stationary support. welding electrode. to running gear, wall, or swarn5.1 10/91 / swarn2.1 9/91 OM-157 745 Page 3 Spool 1 Wire 2 Hub Tension Nut Grasp spool. Turn wrench to adjust nut. while using slight spool, ten When force is needed to turn sion is set. 2 3 Tools Needed: 3 Welding 4 Inlet Wire Guide 5 Pressure 6 Drive Roll 7 Outlet Wire Guide 8 Gun Conduit Cable Lay gun a Wire Adjustment cable out Knob straight. ~ 9/l6in Hold wire tightly to keep it from unraveling. 6 4 (150 mm) Open pressure assembly. in~ (102 mm) Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. ON POWER -*=~ 00FF Close and 1111 Press gun trigger until wire out of gun. Reinstall contact tube and nozzle. comes Remove gun nozzle and contact tube. Set switch. tighten pressure assembly, and let go of wire. II -~ Feed wire to check drive roll pressure. lighten knob enough to ~~r~J/ Cut off wire. Close and latch door. prevent slipping. Ref. ST-161 157/ Ret. ST-159 615-Al Ret. ST.159 216 / S-0627-A Figure 2-4. Feeding Welding Wire OM-157 745 Page 4 2-6. Installing Gas Supply £~ WARNING CYLINDERS can explode if damaged. Keep cylinders away from welding and other electrical circuits. Never touch BUILDUP OF SHIELDING GAS health or kill. Shut off cylinder with Always secure cylinder other stationary support. welding to shielding gas supply can when not in harm use. electrode. running gear, wall, or warn4.1 9/91 Obtain gas cylinder and chain to running gear, wall, or other station ary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of and open valve slightly. Gas flow blows dust and dirt from valve. valve, Close valve. 3 3 CO2 Cylinder 4 0-Ring 5 Regulator/Flowmeter If not supplied, obtain proper regu use with CO2 lator/flowmeter for gas. Install onto gas cylinder so that face is vertical. Flow rate for 6 supplied regulator/ (cubic flowmeter is set to 20 cfh feet per hour). 6 Gas Rose Connection Tools Needed: Obtain and install gas hose. 1-1/8,5/8 in ssb31* 12/92 Figure OM-157 745 PageS 2-5. Installation Of Deluxe Model Regulator/Flowmeter ST-154 583 / ST-154 823 SECTION 3 a WARNING OPERATION READ SAFETY BLOCKS at beginning of manual before proceeding. =~ MOVING PARTS can cause Keep away from pinch points Keep all doors, panels, securely in place ARCING injury. such covers, and as guards damage switch. Do not closed and 1 can change ThicknessNoltage switch position while welding. Arcing inside switch can damage contacts, causing drive rolls. switch to fail. 3 2 / ~S8 1 Insulating Gloves 2 Safety Glasses With Side Shields 3 Welding Helmet Wear dry insulating gloves, safety glasses with side shields, and a welding helmet with a correct shade of filter (see ANSI Z49.1). sb3.1 10/91 Figure 3-1. Safety Equipment 1 Power Switch Use switch to turn unit On and Off. 2 Wire Speed Control Use control to select a wire feed speed. As Voltage switch setting increases, wire speed range also increases. The numbers around the control are speed (see rear 3 not a wire feed cover). ThicknessNoltage Use switch to select Switch an arc voltage. Use Low to weld thin materialand High rear to weld thicker material (see cover). Use wire brush or sandpaper to clean metal at weld joint area. Use chipping hammer welding. to remove slag after Connect work paint-free as close clamp location as on possible to clean, workpiece, to weld area. 5T-159 017 I Ret. ST-157 049 Figure 3-2. Controls OM-157 745 Page 6 SECTION 4- MAINTENANCE& TROUBLESHOOTING - WARNING A~ ELECTRIC SHOCK can M OVING PARTS kill. Turn Oft welding power source, and disconnect input power before inspecting, maintaining, or servicing. HOT PARTS Allow can cause severe cooling servicing. period before can cause injury. Keep away from moving parts. Do not touch live electrical parts. 4f Keep away from pinch points such as drive rolls. burns. maintaining or Maintenance and only by qualified troubleshooting to be persons. performed swarnS 2 2/93 Table 4-1. Maintenance Schedule Maintenance Time Before each After each Tighten use. spool of wire. all connections. Check gun and clean nozzle. Blow out gun liner. Clean and check wire drive Every 3 months. Tape Every 6 months. Blow out 4-1. or replace cracked cables: clean and or vacuum parts; replace as necessary. tighten connections. Replace unreadable labels. inside of unit. Overload Protection READ SAFETY BLOCKS at start of Sectio n 4 before proceeding. A. Overheating Thermostat TP1 protects the unit from damage due to overheating. If main transformer Ti gets too hot, TPi opens and weld output stops. The fan keeps running to cool the transformer. Wait several minutes before trying to weld. B. Motor Fuse Fl Turn Off and unplug door, handle, and remove unit. Unlatch remove door/wrapper. 1 Fuse Fl (See Parts List For Rating) If this fuse opens, the wire drive motor does not run. Push on open. Replace fuse. fuseholder and twist to Reinstall wrapper and handle, and latch door. Tools Needed: 1T~~1ZJfl 1/4,3/Bin ST-159 618 / Ret. ST-I 52 031 Figure OM-157 745 Page 7 4-1. Fuse Fl Location 4-2. Drive Assembly Maintenance I~4s. 7 READ SAFETY BLOCKS at start of Section 4 before proceeding. ______ Turn Off and 1 Wire Cut welding unit. unplug Spool wire off at contact tube. Retract wire onto spool 2 Pressure Roll Arm 3 Cotter Pin 4 Pin 5 Screw 6 Bearing and secure. Remove bearing as shown. Install bearing and secure with screw. Reinstall arm onto pin and secure new with cotter pin. 7 Setscrew 8 Smooth Groove For Hard Wire 9 Drive Roll Remove drive roll as shown. Use a wire brush to clean drive roll. Push drive roll onto shaft with de sired groove in. Turn drive roll so one setscrew faces flat side of shaft, and both setscrews. tighten 10 Knurled Groove For FluxCored Wire 11 Wire Inlet Guide Remove guide by pressing on cutting oft one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place. barbed area or Thread welding wire (see Section 2-5). Close door. Tools Needed: 5/6~1 Ret. ST-159 615-A / ST-154 199 Figure 4-2. Drive Assembly Maintenance OM-157 745 Page 8 4-3. Gun Maintenance READ SAFETY BLOCKS at start of Section 4 before proceeding. 1 FLYING METAL CHIPS AND DIRT Point gun away from people and in a can cause safe direction when injury blowing and damage equipment. out with compressed air. swarrilOl 10/91 Turn Off and Wire 1 unplug unit. Spool Cut welding wire off at contact tube. Retract wire onto spool and secure. Gun Securing Nut 2 Disconnect trigger leads. Loosen nut and leads. remove 3 Nozzle 4 Contact Tube 5 Head Tube 6 Liner Collet Disassemble gun gun and trigger as shown. Liner 7 Pull liner from this end. Blow gun out with compressed air. casing Insert 2 even new liner into gun casing until with end of head tube. Install collet onto liner. Install contact tube and nozzle. Insert gun into feeder and mark where liner touches drive roll. Re move gun and cut liner off. Reinstall gun so that liner is as close as possible to drive rolls without 3 touching. 4 Thread welding wire (see Section 2-5). Close door. 5 7 Tools Needed: 3/8, 5/16 in Rot. 57-159 619-A / Rot. ST-155 509 Figure OM-157 745 Page 9 4-3. Gun Maintenance 4-4. Troubleshooting READ SAFETY BLOCKS at start of Section 4 before proceeding. Table 4-2. Welding Trouble Welding Trouble No weld output; wire does not Section Remedy fee~ -, Secure power cord Motor fuse Fl open, Replace building Secure gun No weld output; wire does not feed; fan motor continues to run, and pilot light -- in plug replace fuse. line fuse trigger receptacle. leads or or reset circuit breaker if open. repair leads, or replace trigger -~ 2-4 -~ ~ -- switch. -- 2-3 -a Thermostat TP1 open (overheating). Allow fan to run; the thermo stat will close when the unit has cooled. 4-lA turns off. No weld output; wire feeds. ---p. Connect work Replace to get good metal-to-metal H contact. Figure 3-2 contact tube. -ru-~ Connect Low weld output. clamp unit to proper 4-3 input voltage or check for low line --L voltage. 2-4 Table 4-3. Wire Drive/Gun Trouble Wire Drive/Gun Trouble Electrode wire feeding stops during Section Remedy -~ Straighten gun cable and/or replace damaged parts. -~ 4-3 welding. Adjust drive roll pressure. Readjust 2-5 hub tension. 2-5 Replace contact tube if blocked. Clean replace or Replace wire inlet drive roll or guide pressure Secure gun trigger leads Check and replace Fl. or or liner if bearing if repair leads, Factory or worn or or plugged. 4-3 -~ 4-2,4-3 slipping. 4.2 replace trigger switch. 2-3 -~ Check and clear any restrictions at drive Have nearest dirty -~ assembly and liner. Authorized Service Station check drive 4-lB 4-2,4-3 ---~ -- motor. OM-157 745 Page 10 SECTION 5- ELECTRICAL DIAGRAMS CR I 2 I z L PLC I 69N. ST-157 378 Figure 5-1. Circuit Diagram For Welding Power Source OM-157 745 Page 11 379-A ~~1 --j SC-157 P2 CORD POWER Source GND SPLIcE Power Welding For Diagram Wiring 5-2. Figure WORK 8A(FM-2~V.) S2 SI SECTION 6 PARTS LIST C0 > E a, U, U, 4 (a a) L. IL. c~:J C,, CD Lf)~ LI~ OM-157 745 Page 13 Part No Description - Mkgs. Figure 1 010909.. 2 3 010910.. 073355.. 4 111998.. 5 111929.. 6.... CR1 120706.. 7 120675.. 8.... FM 111931.. 9 005656.. 10 053297.. Fl 11 *012663.. 12.... VR1 087156.. 13 R2 117116.. 14 Ci 109039.. 15 161439.. 16 108105.. 17 134834.. 18 149322.. 29.... GS1 116996.. 120077.. 20 157190.. Ri 21 119653.. 605227.. 22 23 157187.. 24 089899.. 157376.. 25 26 134464.. +157188.. 27 28 PLG1 113494.. 29 111644.. 30 31 019663.. .... 32 TP1 120638.. Ti 157389.. 33 34 Z 35 36 37 6-1. Main Assembly NUT, SB slflkg hex .375-16 WASHER, flatstl SAE .375 SPRING, cprsn .625 OD x .093 wire x 1 .000 PIN, cotter hair .l2Odia x 2.375 Ig x .500 shaft HUB, spool RELAY, end 24VAC DPDT BRACKET, mtg motor fan MOTOR, fan 115V 50/60Hz 2600RPM .i8i8dia shaft BLADE, fan 6 in 4wg 3odeg .175 bore CW HOLDER, fuse crtg in-line FUSE, mintr gI slo-blo 3A 1 2 1 1 1 1 1 1 1 VARISTOR, 10 joule 68VDC RESISTOR, WWfxd 20W 50 ohm CAPACITOR, elctlt 46000uf 35VDC 1 1 1 STRIP, comb rmr .012 x 1.500 x 9.000 CLAMP, capacitor 2.500dia HOSE, SAE .187 ID x .410 OD (order by ft) CLAMP, hose .405-.485clp dia slfttng VALVE, 115VAC 2 way custom port 1/8 orf (std & deluxe model) BLANK, snap-in nyl sq 1.250 (basic model only) CASE SECTION, front/base/rear RHEOSTAT, WW 25W 25 ohm NUT, nyl hex jam .75ONPST (std & deluxe model) PANEL, side LATCH, slide HANDLE, lifting LABEL, warning general precautionary S2 39 .40 41 42 Si 44 ..45....SR2.... 46 ..47....TE1.... 48 49 1 3ft 2 1 1 1 1 1 1 WRAPPER 1 CORD SET, 125V 5-15P l4ga 3/c 7ft BUSHING, strain relief .370/430 ID x .875mtg hole MOUNT, nprn 15/16 OD THERMOSTAT, NC 1 4 1 1 157447.. TRANSFORMER, pwr main 115 (consisting of) COIL, pwr main 118457.. STABILIZER 1~ 1 CLAMP, grd 200A BUSHING, strain relief .240/.510 ID x .875mtg hole 157305.. SWITCH, rocker DPDT 15A 125VAC 600 325.. CABLE, weld cop strd No. 6 (order by ft) 026 843.. INSULATOR, vinyl blk 119 697.. GA-l6Ci GUN, (Fig 6-3) 025 338.. BUSHING, nyl univ 23/32 hd dia .625mtg hole 097 922.. KNOB, pointer 153 698.. SWITCH, rocker SPST 16A 125VAC NAMEPLATE, (order by model and serial number) 119 264.. RECTIFIER, si iph 100A 200PIV 010 047.. TUBING, stl .625 OD x 1 2ga wall x 1.000 122 385.. TERMINAL ASSEMBLY, chgov (consisting of) 601 835.... NUT, brs hex 10-32 038 887.... STUD, pri bd brs 10-32 x 1.375 010368.. 111443.. 38 .43 Quantity ~ Dia. Item No. 1 1 1 5ft 2 1 1 1 1 1 1 1 8 4 50 .116620.... 51 038618.... 2 52 157 191 LINK, jumper term bd pri BAFFLE,air 1 53 131 336.. ASSEMBLY, wire (Fig 6-2) CLIP, component .437dia mtg adh back REGULATOR/FLOWMETER, dual scale (deluxe model only) FITTING, brs barbed M 1/4tbg x 1/4NPT (deluxe model only) 1 .. 059 712.. 153 714.. 602 958.. *Recommended Spare +When a ordering TERMINALBOARD,chgov 1 DRIVE 1 1 Parts. component originally displaying a precautionary label, the label should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-157 745 Page 14 Item No. Dia. Part No. Mkgs. 131 336 ..1..MOT.. 119 021 ..2 604 657 .5 602 213 010 910 128 189 ..6 602 211 .7 604 538 ..8 10 129 893 126 838 090 416 11 124 817 12 13 151 828 112 031 14 090 443 15 114 415 16 010 224 17 058 085 085 090 092 602 604 605 18 19 20 21 22 23 24 549 242 244 415 237 204 537 853 25 119 028 26 602 169 27 28 601 862 602 203 29 604 673 Quantity Description Figure 6-2. Drive Assembly, Wire (Fig MOTOR, gear 12VDC 80RPM SCREW, .375-16 x 1.250 hexhd sti WASHER, lock stl split .375 WASHER,fIatstlSAE.375 SCREW, .312-18 x 1.750 hexhd sti WASHER, lock stl split .312 WASHER,flatstlSAE.312 INSULATOR, housing drive WIRE DRIVE, (consisting of) PIN, hinge HOUSING, wire drive PIN, cotter hair .042 x .750 LEVER, pressure roll BEARING, ball rdl sgl row .315 x .866 SCREW, 10-24 x .625 flathd-phl stl 6-1 Item x 53) .447 1 PIN, spring CS .187 x 1.000 GUIDE, wire inlet 1/16 FASTENER, pinned WASHER, cupped stl .328 ID x .812 OD x .125 SPRING, cprsn .720 OD x .072 wire x 1.250 KNOB, adj tension WASHER, lock stl ext tooth No. 10 1 1 1 1 1 3 NUT, stl hex full .312-18 1 SCREW, 10-32 x .750 rndhd-slt stl ROLL, drive V groove combination SCREW, set 8-32 x .187 cup pt sch stl NUT, stl hex 10-32 WASHER, lock sti split No. 10 SCREW, 10-32 x .625 flathd-slt sti 3 1 2 1 1 1 5 2. 7 8 12 16 13 14 18- 15 28 Figure 6-2. Drive Assembly, 27 22 26 25 24 7 Wire BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-157 745 Page 15 SC.121 448.C Itern No. Part No. Figure 119 697 1 110793.. 2 110 795 6-3. GA-16C1 Gun (Fig 4 5 110 781 6 6-1 Item 40) HANDLE ASSEMBLY TUBE, head (consisting of) 110780.... NUT, MiOxi 110 779 JACKET, head tube 3 Quantity Description .. .... .... 128 878 .... 7 110 782 .... 8 110786 .... .110789.. 10.. .110794.. 11 080565.. ..12.. ...110797.. .13.. 120714.. .14.. 120715.. 15.. 079974.. 16.. ...110796.. .17.. 047994.. .18.. ...110792.. STOP, nozzle ADAPTER, head tube/nozzle SPRING, nozzle TUBE contact 030 wire (quantity of 1 included with gun) 3 NOZZLE, slip type 1/2 orE 1 TRIGGER SWITCH ASSEMBLY TERMINAL, frict fern .110 x .016 22-18 wire SLEEVE, rbr 2 1 1 LINER, rnonocoil .030-.035 wire w/collet lOft (consisting of) COLLET, liner .035 wire 0-RING, .500 ID x .1O3CS rbr 1 1 2 CONNECTOR, gun/feeder TERMINAL, frict fern .250 x 1 2 .032 22-18 wire CABLE/CONDUIT, lOft 1 9 2 10 12 11 17 18 Figure Ref. SC-lb 832-0 6-3. GA-16C1 Gun BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-157 745 Page 16 thicker + mm) in and ga 0.1046 (2.65 HIGH 90 HIGH 60 12 in ga 14-13 mm) 0.74-89 0.538-67 (1.36-1.7 0.359-478 (1.89-2 8 MEDIUM Not Recomnd Recomnd MEDIU/HG Not 50 MEDIUM 40 MEDIUM 40 MEDIUM 30 MEDIUM 95 LOW 60 LOW 50 LOW 60 LOW 30 LOW 25 LOW 55 100 in ga Thicknes 17-15 mm) in Material STE L MILD WELDING FOR PARMETS SUGETD ga 20-18 mm) -1.21 (0.91 in Than mm) 0. 359 Thin er ga (0.91 20 CONTRL SETINGS Voltage Adjustmen FWeired Adjustmen Control Voltage Adjustmen FWeired Adjustmen Control Voltage Adjustmen FWeired Adjustmen Control SHIELDNG 2 GAS NA OUT in 1/2 STICK WELDING POLARITY SETINGS NA mm) in 1/2 (12.7 DCEN CO mm) 1/4 (12.7 DCEN PROCES 0 0 -.4 01 -4 mm) Cored 0.030 (0.76 Flux in FCAW E-71TGS in mm) Cored 0.035 (0.8 9 Flux FCAW (6.35 DCEP in SIZE TYPE WIRE AND mm) in E-71TGS mm) 0.23- 5 (0.58- 64 GMAW Ste l Solid 696 S-157 Ref.