Download Miller Electric S-42GL Specifications

February 1980
FORM OM-1534
Effective With Serial No. J ~381O51
MODEL
S-42GL
OWN ERS
MANUAL
I
HilliER
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~
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON, WI
54912 USA
ADDITIONAL COPY PRICE 65 CENTS
NWSA CODE NO. 4579
PRINTED IN U.S.A.
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LIMITED WARRANTY
EFFECTIVE: JUNE 1, 1979
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed or implied.
p
.
S
WARRANTY-Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/Dealer that all new and unused Equipment
furnished by Miller is free from defect in workmanship and
material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold sublect to
All
the warranties of their respective manufacturers, if any
engines are warranted by their manufacturer for one year from
date of original purchase.
As
LIMITED
(
submitted by the
In the
specified below, Millers warranty does not apply
to components having normal useful life of less than one 11)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not result from defect in workmanship or material.
as
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tj)
price (less reasonable depreciation based upon actual usel upon
return of the goods at Customers risk and expense. Upon receipt
~i
~
1-J
of notice of apparent defect or failure, Miller shall instruct the clai
mant on the warranty claim procedures to be followed.
L J
$
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTA
PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
TION
required to honor warranty claims pn warEquipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equipment to the original user:
Miller shall be
AS
TO
~$
~
IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EOUIPMENT FURNISHED BY MILLER IS EXANY
V\
CLUDED AND DISCLAIMED BY MILLER.
.
1.
2.
Arc welders, power sources and components
Original main power rectifiers
(labor
.
,
-
EXCEPT
1 year
4.
All other Millermatic Feeders
5.
Replacement
6.
Batteries
or
1 year
3 years
repair parts, exclusive of
AS
labor
.
EXPRESSLY
MILLER
WRITING,
only(
3. Allweldinggunsandfeeder/guns
S
or, where
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ranted
$1
5/
f
breach of warranty or any other duty
the quality of any goods, the exclusive remedies
of Millers
case
option lii repair or 121 replacement
authorized in writing by Miller in appropriate cases, (31
the reasonable cost of repair or replacement at an authorized
Miller service station or 141 payment of or credit for the purchase
.
S
general policy only, Miller may honor claims
original user within the foregoing periods.
with respect to
therefore shall be, at Millers
.
Except
matter of
a
PROVIDED
PRODUCTS
PURCHASE
BY
ARE
BY
MILLER
INTENDED
IN
FOR
COMMERCIAL/INDUSTRIAL
BOdays
ULTIMATE
1 year
60 days
USERS AND FOR OPERATION BY PERSONS TRAINED AND
USE
IN
THE
EXPERIENCED
AND! MAINTENANCE OF
6months
WELDING
EOUIPMENT
AND
NOT
FOR
CONSUMERS
,1
3
OR
.
CONSUMER USE. MILLER
provided that Miller is notified in writing within thirty (30) days
TO,
of the date of such failure
MILLERS
~
t,
..Jt,
AND
4r
NO
RESELLER
WARRANTIES DO NOT EXTEND
IS
AUTHORIZED
TO
WARRANTIES TO, ANY CONSUMER.
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EXTEND
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TABLE OF CONTENTS
Section No.
SECTION 1
1
1
1
1
-
-
-
-
Page
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
-
1.
Introduction
2.
General Precautions
3.
Arc
4.
Standards Booklet Index
SECTION 2
-
1
i
Welding
3
4
INTRODUCTION
2-1.
General
5
2
Receiving-Handling
Description
Safety
5
2
-
-
2.
3.
2-4.
SECTION 3
-
5
5
INSTALLATION
3-1.
2.
3
Location
Drive Motor
5
3
3
Weld Cable Connections
Shielding Gas Connections
5
6
6
6
-
-
-
3.
4.
5
..
ll5VoltsAC Connections
Drive Roll And Wire Guide Installation
Gun Connections
Reinstallation Of Hub And Reel Assembly
.7
3 -9.
InstallationOfReel-TypeWire
7
3-10.
Adjusting
3-5.
3
3
3
-
-
-
6.
7.
8.
SECTION 4
4
4
4
4
.4
-
-
-
-
-
5
5
5
-
-
-
-
Hub Tension
7
7
FUNCTION OF CONTROLS
1.
Inch Button
8
2.
Polarity Switch
8
3.
Arc Control
8
4.
Voltmeter
8
5.
Remote Inch Switch
8
SECTION 5
-
SEQUENCE OF OPERATION
Wire
Threading
Welding (GMAW)
1.
Welding
2.
Gas Metal-Arc
3.
Shutting
SECTION 6
-
Down
8
9
9
MAINTENANCE
Inspection And Upkeep
Cleaning Of Drive Rolls
9
9
6-3.
Fuse
6
Brush
9
9
6
6
-
-
-
1.
2.
4.
SECTION 7
No.
-
Inspection
&
Replacement
TROUBLESHOOTING
1-SAFETY RULES FOR OPERATION OF ARC
SECTION
1-1.
INTRODUCTION
harmful
WELDING
concentrations
exhaust ventilation
We
learn
experience, like a child
wasteful, and unwise. Let the experience of
well
of
toxic
be used,
as
othert teach you.
fumes.
or
the operator must wear
For beryllium, both mutt be used.
Learning safety through personal
touching a hot stove is harmful,
experience.
by
muss
SOURCE.~.
POWER
as
Adequate
lot aI
each person in the
an
ar sa
air-supplied respiratt
coated with or containing materials that emit to
fumes should not be heated unless coating is removed fr
the work surface, the area is well ventilated, or the opera
ic
Metals
Safe practices developed from experience in the use of weld
ing and cutting are described in this manual. Research, devel
opment, and field experience have evolved reliable equipment
and safe installation, operation, and servicing practices. Acci
dents occur when equipment is improperly used or main
tained. The reason for the safe practices may not always be
given. Some are based on common sense, others may require
technical volumes to explain. Is is wiser so follow the rules.
wears
an
r.
m
or
air-supplied respirator.
in a confined space only while it is being vensilat
and, if necessary, while wearing an air-supplied respirator.
Work
Gas leaks in
a
confined space should be avoided. Leaked
at
large quantities can change oxygen concentration dang
ously. Oo not bring gas cylinders into a confined space.
in
Read and
understand these safe practices before attempting
install, operate, or service the equipment. Comply with
these procedures as applicable to the particular equipment
used and their instruction manuals, for personal safety and
for the safety of others.
to
Leaving confined space, shut OFF gas supply at source
possible accumulation of gases in the space if doss
stream
valves have been accidently opened or left opt
to
Check
it.
prevent
Failure so observe these safe practices may cause serious in
or death. When safety becomes a habit, the equipment
can be used with confidence.
so
Vapors
jury
be
sure
that the space is safe before
re-entering
n
n.
from chlorinated solvents
can be decomposed by
he
PHOSGENE, a highly to i ic
gas. and other
eye irritating products. The ult ra
violet (radiant) energy of the arc can also
decompose ri
chloroethylene and perchloroeshylene vapors to form ph
heat of the
These safe practices are divided into two Sections
1
General Precautiuns, common to arc welding and cutting; and
Arc Welding (and Cutting)(only).
2
-
(or flame)
lung and
arc
to form
00
NOT WELD or cut where solvent vapors can be
into the welding or cutting atmosphere or where
he
radiant energy can penetrate to atmospheres
containing e en
minute amounts of trichloroeshylene or
perchloroeshyle ie.
gene.
-
drawn
Reference standards:
Published Standards
available for additional
in
given
those
and
They
this manual.
on safety are
complete procedures
more
are
also
than
listed in the Standards
lndex in this manual. ANSI Z49.1 is the
most
complete.
Electrical Code, Occupational Safety and
Administration, local industrial codes, and local in
spection requirements also provide a basis for equipment in
stallation, use, and service.
The
National
Health
C.
Fire and Explosion Prevention
Causes of fire and
explosion are: combustibles reached by he
flame, flying sparks, hot slag or heated material; mis se
of compressed gases and cylinders; and short circuits.
arc,
AWARE THAT flying sparks or falling slag can p 155
through cracks, along pipes, through windows or doors, ai nd
through wall or floor openings, out of sight of the gogg ed
operator. Sparks and slag can fly 35 feet.
BE
1-2.
A.
GENERAL PRECAUTIONS
Burn Prevention
leather (or asbestos) gauntlet
protective clothing
gloves, hat, and high safety-toe shoes. Button shirt collar and
pocket flaps, and wear cuffless trousers to avoid entry of
sparks and slag.
Wear
-
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease, ~nd
(in electrical parts) of metallic particles that can cause sh~rt
circuits.
Wear helmet with safety goggles or glasses with side shields
underneath, appropriate filter.lenses or plates (protected by
clear cover glass). This is a MUST for welding or cutting, (and
chipping) to protect the eyes from radiant energy and flying
Replace
metal,
cover
glass
when broken, pitted,
or
spattered.
If combustibles
work
in
area:
an
do NOT, weld or cut. Move :he
free of combustibles. Avc ~ id
area
paint
spray rooms, dip tanks, storage areas, ventilators. lf
work cannot be moved, move combustibles at least 35
out
away
See 1-3A,2.
are
if practicable, to
ignition
of
reach
of
sparks
with suitable and
and
heat;
snug-fitting,
he
set
protect agai .555
fire-resistant covers or
or
shields.
Avoid
Hot
oily
or
metal
never
clothing.
greasy
such
electrode
as
be handled without
A
spark may ignite them.
and
stubs
workpieces should
gloves.
Medical first aid and eye treatment. First aid facilities and a
first aid person should be available for each shift
unless medical facilities are close by for immediate treatment
qualified
Walls touching combustibles on opposite sides should not be
welded on (or cut). Walls, ceilings, and floor near w irk
should be protected by heat-resistant covers or shields.
Fire
watcher must be standing by
tinguishing equipment during and for
ing or cutting if:
with
some
suitable
fire
time after we. Id-
of flash burnt of the eyes and skin burns.
a.
Ear plugs should be worn when working on overhead or in a
confined space. A hard hat should be worn when others work
overhead.
b.
intending
B.
to
weld
not be used
by persons
d.
or cut.
Toxic Fume Prevention
combustibles (including building conssr
sion) are within 35 feet
appreciable combustibles are further than 35 feet but
dard
Z49.1
1
listed
in
or visible) in floors or walls within 35
feet may expose combustibles so sparks
combustibles adjacent to walls, ceilings, roofs, or m tal
partitions can be ignited by radiant or conducted heat.
Hot
Standards
index. NEVER ventilate
with oxygen.
Lead
and
work
-,
permit should be obtained before operation
approval that adequate precautions h
supervisors
to
ye
been taken.
After work
is
done, check that
area
is free of sparks,
glow
ng
embers, and flames.
An empty container that held
cadmium
similar
an
ignited by sparks
openings (concealed
ensure
Adequate ventilation. Severe discomfort, illness or death can
result from fumes, vapors, heat, or oxygen enrichment or
depletion that welding (or cutting) may produce. Prevent
them with adequate ventilation as described in ANSI Stan
sc
be
c.
Flammable hair preparations should
appreciable
-,
zinc
-,
mercury
-,
materials, when welded
and
(or
beryllium
-
bearing
cut) may produce
combustibles, or that can ~ ro
duce flammable or toxic vapors when heated, muss never be
welded on or cut, unless container has first been cleanec as
described in AWS Standard A6.O, listed 3 in Standards md sx.
OM-1 534
I~age
1
thorough steam or caustic cleaning (or a
washing, depending on the combustibles
solubility( followed by purging and melting with nitrogen or
carbon dioxide, and using protective equipment as recom
mended in A6.O. Waterfilling just below working level may
substitute for inerting.
This
includes:
solvent
a
water
or
A container with
unknown contents should be cleaned (see
Do NOT depend on sense of smell or sight
determine if it is safe to weld or cut,
Protect cylinders particularly valves from bumps, falls, falling
ob(ects, and weather. Replace caps securely when moving
cylinders.
Stuck
valve.
cylinder
supplier.
Do NOT
valve that
can
hammer
wrench
use
a
not
be opened by hand.
or
to
open
Notify
a
your
paragraph above(.
to
Hollow
or
or
can
castings
cutting. They
containers
be vented before
must
welding
Mixing gases. Never try
to mix any
gases in
a
cylinder.
Never refill any cylinder.
explode,
Cylinder fittings should
Explosive atmospheres. Never weld or cut where the air may
flammable dust gas, or liquid vapors (such as gaso
line(.
contain
3.
never
be modified
or
exchanged.
Hose
Prohibited
0.
use. Never use hose other than that designed for
the specified gas. A general hose identification rule is: red for
fuel gas, green for oxygen, and black for inert gases.
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i, PRECAU
TIONS FOR SAFE HANDLING OF COMPRESSED GASES
IN CYLINDERS, listed 6 in Standards index.
1.
Pressure
Use ferrules
wire
or
or
clamps designed
other substitutel
as
a
for the hose (not ordinary
to connect hoses to
binding
fittings.
No copper tubing splices. Use only standard brass fittings
Regulators
to
splice hose.
relief valve is
Regulator
designed
protect only
regula
from overpressure; it is not intended to protect any
tor
downstream equipment. Provide such protection with one or
more relief devices.
Avoid long runs
ground to keep
wise damaged.
Never
Coil
connect a
the
to
regulator to a cylinder containing
regulator was designed.
gas other
excess
to prevent kinks and abuse. Suspend hose off
it from being run over, stepped on, or other
hose so prevent kinks and
tangles.
than that for which the
Protect
Remove faulty regulator from service immediately for repair
(first close cylinder valve(. The following symptoms indicate
a
slag,
hose
from
damage by sham edges, and by sparks,
and open flame.
Examine
faulty regulator:
tions.
if gas leaks externally.
Leaks
if delivery pressure continues
Excessive Creep
downstream valve closed.
leaks.
-
-
hose regularly for leaks, wear, and loose connec
Immerse pressured hose in water; bubbles indicate
to
rise with
Repair leaky
or
hose by
worn
cutting
area out
and
splicing
if gauge pointer does not move off stop pin
Faulty Gauge
when pressurized, nor returns to stop pin after pressure
fl-2D3l. Do NOT
release.
4.
Repair. Do NOT attempt repair. Send faulty regulators for
designated repair center, where
repair to manufacturers
special techniques and tools are used by trained personnel.
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator. Except
-
2.
for
use
tape.
Proper Connections
hydrogen,
crack valve momentarily, pointing outlet away
sources of ignition. Wipe with a clean lint-
from people and
less cloth.
Cylinders
Cylinders must be handled carefully to prevent leaks and
damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including third
rails, electrical wires, or welding circuits. They can produce
short circuit arcs that may lead to a serious accident. (See
Match
regulator to cylinder. Before connecting, check that
regulator label and cylinder marking agree, and that the
regulator inlet and cylinder outlet match. NEVER CON
NECT a regulator designed for a particular gas or gases to a
cylinder containing any other g~.
the
1-3C.(
ICC
or
DOT marking
assurance
of safety when the
Identifying gas
marked
tent.
on
content.
them; do
Notify supplier
name,
number,
or
be
must
on
cylinder
rely
is
on
if unmarked. NEVER DEFACE
other
an
cylinders with name of gas
color to identify gas con
Use only
not
cylinder. It is
properly handled.
each
markings
on
a
cylinder. It
or
is
alter
illegal
Tighten connections. When assembling threaded connections,
clean and smooth seats where necessary. Tighten. If connec
tion leaks, disassemble, clean, and retighten using properly
fitting wrench.
Adapters. Use a CGA adapter (available from your supplierl
between cylinder and regulator, if one is required. Use two
wrenches so tighten adapter marked RIGHT and LEFT
and hazardous.
HAND threads.
Empties: Keep valves closed, replace caps securely; mark MT;
keep them separate from FULLS and return promptly.
Regulator outlet (or hosel connections may be identified by
right hand threads for oxygen and left hand threads (with
grooved hex on nut or shankl for fuel gas.
Prohibited
use.
Never
use
a
cylinder
than its intended use, NEVER
Locate
or
secure
cylinders
Passageways and work
so
areas.
or
its contents for other
support
as a
or
5.
roller.
be knocked
over.
Keep cylinders clear of
areas
they
cannot
where they may be struck.
Pressurizing Steps:
Drain regulator of residual gas through suitable vent before
opening cylinder (or manifold valve( by turning adjusting
screw in (clockwise(. Draining prevents excessive compression
heat at high pressure seat by allowing seat to open on pressur
ization. Leave adjusting screw engaged slightly on single-stage
regulators.
Transporting cylinders. With a crane, use a secure support
such as a platform or cradle. Do NOT lift cylinders off the
ground by their valves or caps, or by chains, slings, or mag.
nets.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in
slowly. When gauge is pressurized (gauge reaches regu
leave cylinder valve in following position:
For oxygen, and inert gases, open fully to seal stem against
poasible leak. For fuel gas, open to less than one turn to
permit quick emei~ency shutoff.
creases
Do NOT expose cylinders so excessive heat, sparks, slag, and
flame, etc. that may cause rupture. Do not allow contents to
exceed
exists.
Page
2
130F.
Cool with
water
spray where such exposure
lator maximuml
operation with low-reflective, non-combustible screens
Allow for free air circulation, particularly at fl
Use pressure charts (available from your supplier( for safe
and efficient, recommended pressure settings on regulators.
panels.
or
or
level.
pressurization and regularly shere
(capful of Ivory Liquid* or
equivalent per gallon of water(. Bubbles indicate leak. Clean
Check
for leaks
after.
Brush with
first
on
soap solution
Viewing the weld. Provide face shields for all persons
looking directly at the weld.
v
ho
will be
off soapy water after test; dried soap is combustible.
Others working in
E.
User
Responsibilities
Remove leaky or defective equipment from service immed
iately for repair. See User Responsibility statement in equip
ment
F.
Leaving Equipment Unattended
at source and drain gas.
C.
weld, make
to
sure
that
screen
flaps
or
tay
closed.
a
carries
hot, and compressed gases
ments are
currents
precautions
The
is intense and
can
rated
in 1-2C.
Do
capacity.
not
Is may overheat cables and
overload
cause
a
welc
arc
ing
fire.
Loose cable connections may
fire.
overheat
or
flash and caus~
a
Never strike an
brittle
creates a
to
such
a
arc
on
area
a
that
cylinder
can
or
cause
other pressure vessel Is
violent rupture or I ~ad
a
rupture later under rough handling.
D.
Compressed Gas Equipment
E.
Shock Prevention
in 1-2D.
Exposed hot conductors or other bare metal in the welc ing
circuit, or in ungrounded, electrically-HOT equipment ;an
fatally shock a person whose body becomes a conductor. DO
NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet ur
face when welding, without suitable protection.
Clothing
To protect
long-sleeve clothing (particularly for gas-shielded arc(
Wear
precautions
Comply with precautions
visibly bright. Its radiation
WITH PRECAUTIONS.
Protective
with
Equipments
in 1-2.
welding
damage eyes, penetrate lightweight clothing, reflect from
light-colored surfaces, and burn the skin and eyes. Skin burns
resemble acute sunburn, those from gas-shielded arcs are
GET BURNED; COMPLY
more severe and painful. DONT
arc
Explosion Prevention
may be used. The wise
Burn Protection
with
be vented to the outside air.
must
at
operator avoids unnecessary risks and protects himself and
others from accidents. Precautions are described here and in
standards referenced in index.
Comply
Fire and
equipment.
high
equipment
significant voltages. The arc is very bright and hot, Sparks fly,
fumes rise, ultrdviolet and infrared energy radiates, weld
trouble. The
invites
Toxic Fume Prevention
Comply
1-1, 1-2, and this section. Arc
safe process, but a careless opera
in
precautions
Comply
Welding, properly done, is
outergarments of untreated
against shock:
in
addition to gloves, hat, and shoes (1-2A(. As necessary, use
additional protective clothing such as leather (acket or
sleeves, flame-proof apron, and fire-resistant leggings. Avoid
cotton.
Keep body and clothing dry. Never work in damp area w th
out adequate insulation against electrical shock. Stay o
dry duckboard, or rubber mat when dampness or sweat ;an
not be avoided. Sweat, sea water, or moisture between b idy
redi. ces
and an electrically HOT part
or grounded metal
the body surface electrical resistance, enabling dangerous md
lethal
currents to flow through the body.
possibly
-
Bare skin protection. Wear dark, substantial clothing. Button
collar to protect chest and neck and button pockets to pre
vent entry of sparks.
Grounding
1.
2.
fI ssh
or cut
ARC WELDING
1.
are
Generator engine exhaust
Carbon monoxide can kill.
with
A.
wearing
Comply with precautions in 1-2B.
Rope Staging-Support
tor
starting
Before
doors
B.
Rope staging-support should not be used for welding
ting operation; rope may burn.
1-3.
are
manual.
Close gas supply
C.
See that all persons
area,
goggles.
the
-
Equipment
Eye and Head Protection
installing, connect the frames of each unit such as
welding power source, control, work table, and water circ ml ator to the building ground. Conductors must be adequati to
carry ground currents safely. Equipment made electric ml ly
HOT by stray current may shock, possibly fatally. Do N OT
GROUND to electrical conduit, or to a pipe carrying A
gas or a flammable liquid such as oil or fuel.
When
Protect eyes from exposure to
tric arc without protection.
Welding
12
or
helmet
denser
or
must
before striking
can
elec
arc.
a
clear
broken helmet
or
an
shield containing a filter plate shade no.
be used when welding. Place over face
Protect filter plate with
Cracked
radiation
NEVER look at
arc.
pass
through
or
cover
plate.
shield should
to cause
NOT be worn;
burns.
Cracked, broken, or loose filter plates must be replaced IM
MEDIATELY. Replace clear cover plate when broken, pitted,
or
Three-phase connection. Check phase requirement of eqi
If only 3-phase power is availa
ment before installing.
connect single-phase equipment to only two wires of
3-phase line. Do NOT connect the equipment ground leas
the third (live) wire, or the equipment will become elec
a dangerous condition that can shock, possi
cally HOT
fatally.
-
the
to
sri
bly
spattered.
Before
Flash goggles with side shields MUST be worn under the
helmet to give some protection to the eyes should the helmet
not be lowered over the face before an arc is struck. Looking
at an arc momentarily with unprotected eyes (particularly a
high intensity gas-shielded arc( can cause a retinal burn that
may leave
3.
lip
)le,
a
permanent dark
area
in the field of vision.
Protection of Nearby Personnel
tors
welding, check ground for continuity. Be sure
touching bare metal of equipment frames at
are
conc uc
conr ec
tions.
If
with the eqi
lip-
for connection to a switchbox, connect the ground I
to the grounded switchbox. If a three-prong plug is added
connection to a grounded mating receptacle, the ground I
must be connected to the ground prong only. If the line c
tad
for
a
line cord with
a
gnund
lead is
provided
ment
tad
)rd
with a three-prong plug, connect to a grounded ma ing
receptacle. Never remove the ground prong from a plug or
use a plug with a broken off ground prong.
comes
Enclosed
room
or
welding
area.
encJosed bay
For production welding, a separate
is best. In open areas, surround the
Trademark of Proctor & Gamble.
OM-1534
~age3
2.
Do
Electrode Holders
If,
Fully insulated electrode holders should be
holders with protruding screws.
used.
not
in
open power circuit or change polarity while welding.
emergency, it must be disconnected, guard against
an
shock burns,
Do NOT
or
flash from switch
arcing.
use
3.
Leaving equipment unattended. Always shut OFF and dis
all power to equipment.
Connectors
connect
Fully insulated lock-type
welding cable lengths.
connectors
should be used
to
Power disconnect switch must be available
join
power
1-4.
near
the
welding
source.
STANDARDS BOOKLET INDEX
Cables
4.
For
cables for wear, cracks and damage.
REPLACE those with excessively worn or
lethal shock from
damaged insulation to avoid possibly
bared cable. Cables with damaged areas may be taped to give
resistance equivalent to original cable.
Frequently
inspect
information, refer to the following standards
comply as applicable:
more
or
their latest revisions and
IMMEDIATELY
-
Keep cable dry, free of oil and grease, and protected from
hot metal and sparks.
1.
ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 2501 NW 7th St., Miami, FIa. 33125.
2.
ANSI Standard Z87.1, SAFE PRACTICE FOR OCCUPA
TION AND EDUCATIONAL EYE AND FACE PROTEC
TION, obtainable from American National Standards
Institute, 1430 Broadway. New York, N.Y. 10018.
3.
Standard A6.0, WELDING
CONTAINERS WHICH HAVE HELD
COMBUSTIBLES, obtainable same as item 1.
Terminals And Other Exposed Parts
5.
Terminals and other
have
insulating
covers
exposed parts of electrical
secured before operation.
units should
American
AND
Electrode Wire
6.
51, OXYGEN-FUEL GAS SYSTEMS
AND CUTTING, obtainable from the
Protection Association, 470 AtlantIc
Avenue, Boston. Mass. 02210.
Standard
FOR WELDING
Fire
National
4.
NFPA
5.
NFPA Standard SiB, CUTTING AND WELDING PRO
CESSES, obtainable same as item 4.
interlocks and Circuit breakers should
shunted out.
6.
Before installation, inspection, or Service, of equipment, shut
OFF all power and remove line fuses (or lock or red-t~
switches) to prevent accidental turning ON of power. Discon
nect all cables from welding power source, and pull all 115
CGA Pamphlet P-i. SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 500 Fifth Avenue, New
York. N. V. 10036.
7.
OSHA Standard 29 CFR, Part 1910, Subpart 0, WELD
ING, CUTTING AND BRAZING.
Electrode wire becomes electrically HOT when the power
switch of gas metal-arc welding equipment is ON and welding
gun trigger is pressed. Keep hands and body clear of wire and
other HOT parts.
7.
Safety Devices
Safety
as
not
or
devices such
be disconnected
volts line-cord
plu~.
8.
Code for Safety in
W117.2.
Page
4
Welding Society
CUTTING
Welding
and
Cutting, CSA Standard
SECTION 2
Electrode Wire
Diameter
INTRODUCTION
Electrode Wire
Capacity
Feed
Arc
Weight
(Pounds)
Speed
Dependent On
1/16-1/8
Overall
Dimensions
Voltage
(Inches)
Height
Width
-
-
Length
-
Net
~
25
16-3/4
28-1 /2
108
103
~
Figure 2-1. Specifications
2
1. GENERAL
This manual has been prepared
especially for use in familiarizing personnel with the
design, installation, operation, maintenance, and
troubleshooting of this equipment. All information
presented herein should be given careful consideration
to assure optimum performance of this equipment.
2
2
manual:
-
-
2.
RECEIVING-HANDLING
Prior to installing
equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill of
lading and freight bill will be furnished by the carrier on
-
-
4. SAFETY
Before the equipment is put mt
operation, the safety section at the front of this manu
should be read completely. This will help avoid possibl
injury due to misuse or improper welding applications
-
-
The
following definitions apply to CAUTION, IMPOF
TANT, and NOTE blocks found throughout thi
this
request if occasion
t~tJklL.]~ Under
Under
IMPORTANT
2
-
requesting
designed
use
to
-
This unit is
a
operate from the
heavy-duty wire
voltage of a
arc
It is
designed
primarily with flux-cored wires~or self-shielding
constant current
for
information
3. DESCRIPTION
feeder
heading,
installation
to file claim arises.
concerning this equip
ment, it is essential that Model Description and Serial
Number of the equipment be supplied.
When
this
operating, and maintenance procedures or practices wi I
be found that if not carefully followed may create
hazard to personnel.
welding
power
source.
this
heading,
installation
______________
opera ting, and maintenance procedures or practices wi I
be found that if not carefully followed may result i
damage
to
equipment.
I~IsIl~ Under this
heading, explanatory statement
special emphasis to obtain th
operation of the equipment.
will be found that need
most
efficient
wires.
SECTION 3
-
INSTALLATION
sidered when
installing the unit. It is recommended th~ t
the unit be located close to the work area for ease i
connecting the control/feeder
work
clamp. Suitabl
space should be maintained around the unit for makin
necessary connections and for maintenance function~
3
2. DRIVE MOTOR
The drive motor is provide
must be removed pric
to operation of the control/feeder. Remove the sid
panel of the unit to gain access to the motor. A long
nose pliers should be used to remove the plug from th
top of the motor gear case.
-
with
a
gear
case vent
IMPORTANT
-
plug which
Damage
r
to the motor may result if th
______________
vent
plug is
not removed
3 -3. WELD
1c045 405
Figure 3-1. Dimensional Drawing
1. LOCATION
A proper installation site should
be selected for the control/feeder if the unit is to pro
vide dependable service. Lead lengths must be con-
3
-
-
CABLE
prior
to
operation.
CONNECTIONS
-
A
wel
cable terminal is
provided inside the wire reel shroud c
the control/feeder for connecting the weld cable froi
the welding power source.
If DC Straight Polarity is used, the cable from th
welding power source Negative output terminal is cor
nected to the control/feeder.
OM-1534P
ge5
If DC
Reverse
welding
power
Polarity is used, the cable from the
source
Positive output terminal is
con
nected to the control/feeder.
U~sI I ~ Ensure that the POLARITY switch
on
trol/feeder corresponds with the weld cable
the
con
connec
tions. If the switch is in the wrong position, the elec
trode wire will retract into the gun when an arc is struck.
IMPORTANT: Ensure that the weld cable terminal is
kept clean
at all times. Also ensure that the nut on this
terminal is
secure.
If either
one
of the above conditions
is not met, erratic weld current and wire feed could
result.
GAS
SHIELDING
3 -4.
(Optional) Route a gas hose
the gas fitting on the right side
ting has right-hand threads.
CONNECTIONS
from the gas supply to
of the control. This fit
-
11
10
11
10
TB-047 931
Figure 3-2. Drive Roll Installation
3
5. 115 VOLTS AC CONNECTIONS
With Optional Shielding Gas Capability)
(Models
-
The gas
For
valve in this control/feeder requires 115 vac to func
tion. Connect the power cord from the control/feeder
pair
to a
115
vac
power
supply
when
use
-
(10 & 15) and slide a drive roll onto the drive gear
(8) and pressure gear (13) with screw in line with
holes. Insert remaining
one of the threaded
screws (10 & 15) and tighten.
of the gas valve is
desired.
6. DRIVE ROLL AND WIRE GUIDE INSTALLA
TION (Figure 3-2)
Upon initial installation, or as a
result of changes in wire size and type, it is necessary to
install the required drive rolls and wire guides.
3
-
-
~ Base selection of drive rolls upon the follow
ing
1.
split drive rolls (12 & 16): align holes on each
of split drive rolls, insert a securing screw
recommended usages.
U-Groove rolls for soft and soft shelled cored wires.
U-Cog rolls for extremely soft shelled wires (usually
surfacing types).
3. Spilt V-Knurled rolls for hard shelled cored wires
(seff-shielding and C02 shielded types).
4. Drive roll types may be mixed to suit particular re
quirements (example: V-knurled roll in combination
with U-groove).
2.
hard
One-piece
drive rolls (9 & 14) are of the dou
When. the grooves become worn,
reverse each drive roll, locating the unused groove in
position to feed the wire.
t~I.~I~
ble
usage type.
drive rolls (12 & 16) are of the double usage type..
When the knurled groove of the drive rolls becomes
worn, the spilt halves ~3?~D~teversed so ~that the un
used edges will now provide a new knurled groove.
Spilt
I~sII~ To
drive
on
ensure proper gripping action of U-Cog
rolls, both rolls should be installed showing slots
the side
or
both should show the side without slots.
Also, it is
necessary to line up the blunted teeth on the
pressure gear roll directly over the spaces between the
teeth
on
the drive gear roll.
Having selected the appropriate drive rolls and wire
guides, proceed to the following installation instruc
tions:
A.
1.
2.
Drive Roll Installation
(Figures 3-2
& 3-3)
Loosen pressure adjustment wing nut (item 2,
Figure 3-2) and pivot it free of the cover.
Pivot gear
cover
(3) away
to expose pressure
gear.
Slotted Side
Of Drive Roll
3.
Loosen and
(10 & 15)
4.
For
one
on
remove
the three
securing
screws
each gear (8 & 13).
piece drive rolls (9 & 14): slide
a
drive roll
the drive gear (8) and pressure gear (13)
with holes aligned and secure with screws (10 &
onto
15).
Page 6
Terminal
TA-047 932
Figure 3-3.
U-Cog
Drive Roll Installation
L8.
1.
lnllet ~Fh~e Guide
1.
(Figure 3-2)
Loosen the inlet wire
guide securing
X2J~sL~ ~ Wire guides should be installed
of the
guide is as close
without touching.
2.
Insert the inlet wire
Secure by
guide into
tightening
screw
as
drive
(1).
tip
possible
(1).
bolt (11) thereby moving the drive roll in or out to the
desired position. The drive roll on the pressure gear will
locate itseff on the wire when the gear cover is replaced
-
spindle
su
Flat Washer (13)
C.
Hub (12)
D.
Wire Reel (11)
Flat Washer (8)
G.
Fiber Washer (7)
Keyed Washer (6)
H.
Spring (5)
I.
Flat Washer (4)
2.
Rotate hex nut (3) onto support shaft (15). H
nut (3) should be rotated only until a slight dr~
is felt while turning hub (12).
3.
Depress the two spring loaded stops (1) on tl
retaining ring (2) and slide the retaining ring t a)
into proper position on the hub (12). Release ti
together.
housing
is made with
mounting
holes of
sufficient clearance to provide adjustment of the wire
guides up or down in relation to the drive rolls. This ad
justment has been factory set, but if readjustment
becomes necessary, loosen mounting bolts (item 5,
Figure 3-2), nut (7) and bolt. Slide the wire drive hous
ing upward or downward until the wire can be fed
straight through the guides while seated in the drive roll
groove. Tighten mounting bolts (5) bolt and nut (7).
3
Fiber Washer (14)
B.
F.
Behind the drive gear is a spring washer(s). To
obtain proper alignment of the drive roll on the drive
gear with the wire guides rotate the drive gear securing
The wire drive
items onto the
A.
E.
assembly.
~
and the gears mesh
following
port shaft (15) in order given:
that the
so
the drive roll
to
screw
Slide the
two
4.
stops (1).
Proceed to install
welding wire according
to Se
tion 3-9.
2
3
4
5
6
7
8
9
10
11
7. GL~ CO~ECTIONS
A.
Outlc~ ~9irc Gu~de
(Figure 3-2)
gun/feeder
(item 6, Figure 3-2).
connector
1.
Loosen
2.
Insert gun.
1,~
securing
knob
14
Wire guides should be installed so that the tip
guide is as close to the drive roll as possible
without touching.
~
of the
3.
Tighten gun/feeder
connector
securing
knob
(6).
~.
TD-056 132 D
Gun T~9er (l~
Figure
Applicable)
3
is provided for making gun trig
ger control connections. Align keyways and insert the
plug from the gun into the Trigger receptacle and rotate
The
the
Trigger receptacle
plug
C.
-
9.
3.
on the drive assembly provides
point for connecting the weld cable from the gun (if so
equipped).
-
8.
fl~GTALLATlON
ASSEI~~LY
(FIgure
3-4)
OF
-
If
HUB
it
WIR E
wing nuts (item 9, Figure 3-~
fingers (10) of the wire reel (11).
fingers (10)
out until
they
b
can
Install the wire onto the reel (11)
AND
should
REEL
become
necessary to replace any part of the assembly, obtain
part and proceed as follows to reinstall the assembly.
over
the foL
fingers (10). Ensure that the wire feeds off
th
bottom of the reel (11). The reel (11) turns in
clockwise direction.
a
r
B
a
Rotate the four fingers (10) back to their prop~
position. Tighten the four wing nuts (9).
Applicable) (Figure 3-2)
The weld cab!e terminal
3
REEL-TYPE
rotated toward the center of the reel (11).
4.
a
the
Pull the four
2.
integral gas input fitting is provided on the wire drive
assembly for guns utilizing this type of connection. If
the gun requires a separate shielding gas connection,
connect the gas hose from the gun to the fitting on the
front of the control. This fitting has right-hand threads.
Wa~d Cable (~f
OF
Loosen the four
1.
on
An
D.
INSTALLATION
(Figure 3-4)
threaded collar clockwise.
~din~j Gas (If Applicable)
3-4. Hub And Reel Installation
3-10. ADJUSTING
HUB
TENSION
(Figur a
Check hub tension by slowly pulling wire towar d
3-4)
the feed roll. The wire should unwind freely, but the hu b
-
tension should be sufficient to keep the wire taut an d
prevent backlash when the control/feeder is shut off. I
adjustment is required, loosen or tighten the hex n~ It
(item 3, Figure 3-4)
shaft (15)
on
the end of the spindle
suppo
.t
accordingly.
OM-1534F age7
SECTION 4
4
1.
-
~NCH BUTTON
button is
it
(Figure 4-1)
The INCH push
-
contact switch. When
monentary
a
completes the circuit
FUNCTION OF CONTROLS
-
to the motor without
depressed
having to
Fuse
strike an arc. This switch will permit inching of the wire
at whatever setting the ARC CONTROL is at.
Inch Button
The
~~4*J~J~
welding wire and all metal parts in
contact with it are energized while the welding power
source is energized. Do not touch the welding wire or
any metal part making contact with it.
4
2.
POLARITY
SWITCH
Polarity Switch
(Figure 4-1) The
that the wire drive motor
feeds wire for both DC Straight and DC Reverse Polari
-
POLARITY switch
-
ensures
ty.
Arc Control
If DC Straight Polarity is used, the switch must be in the
STRAIGHT (ELECTRODE NEGATIVE) position.
IF DC Reverse Polarity is used, the switch must be in
the REVERSE (ELECTRODE POSITIVE) position.
Ensure that the weld cable from the
~IIl~
welding
power source is connected to the appropriate output
terminal for the polarity desired. If the weld cable con
nections and POLARITY switch do not
TC-045 405
Figure
correspond, the
electrode wire will retract into the gun when
struck.
an arc
is
welding power source has a high or low
voltage, the wire speeds may be correspondingly
faster
3. ARC CONTROL (Figure 4-1)
The ARC CON
TROL provides a means of determining the rate at
-
or
slower.
-
which
the
welding wire will
ARC
be fed into the weld.
in
CONTROL
a
clockwise
decrease the rate of wire feed and
the
Rotating
direction
will
thereby provide
Rotating
arc.
a
4
4. VOLTMETER (Optional)
The voltmeter will
indicate load (or welding arc) voltage while welding.
The. voltmeter will indicate the voltage applied to the
-
-
motor circuit when
The ARC CONTROL is calibrated in percent and should
not be misconstrued as an actual inch per minute
reading.
SECTION 5
-
4
-
-
The Remote Inch switch functions in the same manner
as the INCH switch on the unit. The INCH switch on the
unit is also functional.
SEQUENCE OF OPERATION
1. WELDING WIRE THREADING
R~i~ULf~
through the
Prior
the
threading
to
gun, ensure
available at the weld head.
that
welding
weld power is
1.
Install the wire
as
approximately
wire
not
I~IsI1~ If when the gear cover is closed the
instructed in Section 3-9.
are not
Cut off any portion of the free end of the wire
which is not straight. Ensure that the cut end is
free
from
rough
surfaces
to
permit
5.
Loosen the wing nut
adjustment, pivot the
proper
of
the
cover,
assembly
4.
and
the drive roll pressure
adjustment free
pivot the pressure gear
Feed the wire
pressure
through the
on
tooth.
Pivot the gear cover closed making sure the
on the pressure gear mesh with the teeth
on the drive gear. The welding wire must also be
in the grooves of the drive rolls.
on
away until it is in
the drive rolls, and
one
teeth
feeding.
3.
U-Cog
aligned properly (see Section 3-6),
pivot the gear cover away from the drive gear and rotate
the pressure gear
2.
4 inches of wire into the
outlet wire guide.
drive rolls
8
depressed.
5. REMOTE INCH SWITCH (Optional)
The
Remote Inch switch provides the operator the ability to
control inching of the welding wire from the work area.
Feed
Page
the INCH button is
ARC
CONTROL in a
counterclockwise direction will increase the wire feed
rate and thereby provide a shorter arc.
longer
-
Components
I~S1l~ If the
arc
4
4-1. Control
an
open
inlet wire
6.
Pivot the pressure adjustment wing nut until the
washer on the pressure adjustment is seated on
top of the gear cover.
7..
Turn
position.
guide, past
guides.
into the outlet wire
the
pressure
adjustment wing
clockwise direction until the drive rolls
nut
are
in
a
tight
against the welding wire. Do not overtighten.
Further adjustment to attain desired clamping
pressure can be made after the welding power
source
8.
9.
and the control/feeder
are
Close the
6.
trigger sw~itch
to
initiate gas flow; if ap
plicable.
put into opera-
Touch the
7.
welding
wire to the
workpiece
to sta
tion.
wire feed.
Draw the gun cable out straight.
is noticed, tighten the drive ro~l
adjustment wing nut 1/2 tur,~
Repeat until slippage stops. Do not
overtighten wing nut.
Energize the welding
power
If wire
slippage
pressure
clockwise.
source.
.1AUIIsJ~r The
we/ding wire and all metal parts in
energized while the welding power
source is energized. Do not touch the welding wire or
any metal part making contact with it.
contact with it are
10.
Depress the INCH switch. This will run the
welding wire through the gun. Release the INCH
switch when the welding wire extends approx
imately one inch out of the gun tip.
The
contact with it are
touch the
tact with it.
8.
To stop wire
feed, pull the
gun away from th
workpiece.
5 -3. SHUTrING DOWN
5 -2. GAS METAL-ARC WELDING (GMAW)
1.
Break the
2.
Open the trigger switch
plicable.
3.
Advance the wire
instructed in
1.
Make all necessary connections
Section 3.
2.
Place the POLARITY switch in the proper posi
tion.
3.
Rotate the ARC CONTROL to the desired set
as
welding wire and all metal parts /4
energized while welding. Do nc t
welding wire or any metal part making coi
CAUTION
____________
arc.
so
to
stop gas flow, if ap
that there is
inch stic
a one
out.
ting.
shielding
4.
Turn
5.
Energize the welding power
on
4.
Shut the
welding
5.
Turn off
shielding
power
source
down.
applicable.
gas at source, if
gas at the
source.
source.
CAUTION If
welding, it/s imperative that pro
protective clothing (welding coat and gloves) and
protection (glasses and welding helmet) be put on.
CAUTION: Prior to
per
eye
Failure to
comply
bodily damage.
may result in serious
or
permanent
SECTION 6
-
UPKEEP
1. INSPECTION AND
Usage and
shop conditions will determine the frequency and type
of maintenance. Inspect equipment as follows:
6
-
-
welding /s performed in a confine
off the shielding gas supply coul
failure
turn
to
area,
result in a build-up of gas fumes, thereby endanger/n
personnel reentering the welding area.
___________
MAINTENANCE
2. CLEANING OF DRIVE ROLLS
Occasional y
it will become necessary to clean the wire groove on t~ e
drive rolls. This cleaning operation can be performe d
6
-
-
with
welding
Make
2.
Inspect gun for broken areas, cracks and loose
parts: tighten, repair, and replace as required.
3.
Carefully
sure
remove
power
source
any weld spatter
or
4.
a
hardwood stick,
never a
metal tool.
Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked in
sulation and areas where it enters equipment.
5.
Remove grease and grime from components;
moisture from electrical parts and cable.
6.
Blow out the gun wire guide liner with com
pressed air when changing wire. This will remove
any metal chips and dirt that may have ac
cumulated.
wire brush.
To clean the wire grooves it will be necessary to fir t
remove the drive roll(s) (see Section 3-6 for removal an d
installation instructions).
foreign
matter which may accumulate around the nozzle
orifice. Use
a
is shut down.
1.
I~ii1~ Failure to
the
properly maintain the drive rolls ca
build-up of wire particles which will decrea~ 9
efficiency of the wire feeding operation.
6
3. FUSE
result in
a
(Figure 4-1) The control is protecte
damage due to an internal short or excessiv 3
overload by fuse Fl. Should Fl open, the control woul
be completely inoperative.
-
-
from
6
-
4.
BRUSH INSPECTION
6-1 & 6-2)
b
REPLACEMEN r
(Figures
1.
Shut down the
welding
power
source.
OM-1534
age9
CAUTION
P/acing
the
we/ding
power
source
7.
Connect
new
brush
pigtail
brush box tab.
to
___________
POWER switch in the OFF position does not remove
power from all internal circuitry. Completely terminate
8.
tempting any inspection or work on the inside of the
unit. If the we/ding power source is connected to a
disconnect switch, padlock the switch in an open posi
tion. If connected to a fuse box, remove the fuses and
padlock the cover in the closed position. If the unit is
connected to
a
device without
device to
warn
circuit breaker,
other
or
attach
a
red tag to the
being worked
on.
2.
pigtail through slot in
pigtail will not come
brush box. Ensure
into contact with
a
metal surface.
9.
Insert brush into brush box. Ensure that the low
end of the bevel
towards the
on
the top of the brush is
spring.
Long-Nose Pliers
disconnecting
others that the circuit is
locking facilities,
Route
that the
all electrical power to the we/ding power source by
employing machinery lockout procedures before at
Brush Box
Tab
Open brush cap by sliding screwdriver under
catch and lifting. Remove brush cap.
Spring
Brush Box
NOTE:
Spring
bly
assem
hooks here.
TA-046 226
Brush
Spring Retaining
Figure 6-2. View Of Spring Assembly And Brush
Bracket
From Armature End Of Motor
Brush
Pigtail
10.
TA-046 226
Using long-nose pliers insert spring assembly
sliding the spring retaining bracket
along the brush box wall. The spring retaining
beside brush
Figure 6-1. View Of Spring Assembly And Brush
When Brush Cap Is Opened
hooks
bracket
lustrated in
3.
Grasp spring retaining
bracket with
on
the
brush
box
wall
as
il
Figure 6-2.
long-nose
11.
pliers.
If the
spring retaining bracket is in place, it will be
the brush box wall when the pliers are
against
4.
Push spring retaining bracket in lightly and move
towards brush. This should release the spring
assembly and it can be removed.
released.
12.
Ensure that the
illustrated in
spring is in the
Figure 6-1.
proper
position
as
using brush pigtail.
5.
Pull brush out
6.
replacement is necessary (brushes are less
than 1/4 in length) disconnect the brush pigtail
13.
Replace and latch the brush
cap.
If
from the brush box tab and
remove
brush.
14.
Reconnect power to all equipment and
resume
operation.
SECTION 7- TROUBLESHOOTING
voltages are present on the in
as long as power is con
before
attempting any in
power
CAUTION Hazardous
ternal
circuitry of this unit
nected.
Disconnect
spection or work on the inside of the unit.
Troubleshooting of internal circuitry should be per
formed by qualified personnel only.
Use this chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these pro
cedures, the nearest Factory Authorized Service Sta
tion should be contacted. In all cases of equipment
malfunction, the manufacturers
should be strictly followed.
The following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
tW
this unit.
limited to brush
It is assumed that proper installation has been made, ac
to Section 3 of this manual, and that the unit
has been functioning properly until this trouble
cording
developed.
Page 10
Wire
recommendations
drive motor repairs should be
replacement (see Section 6-4). Attemp
ting further repairs may result in personnal injury in ad
dition to motor damage. Warranty is void if the motor is
tampered with. For further repair and replacement in for
mation contact the Factory Service Department.
No weld output
or
REMEDY
PROBABLE CAUSE
TROUBLE
erratic
weld output.
in
Defect
welding
power
~
See
troubleshooting
source
source.
owners
information in
Ensure all weld cable connections
Loose connections.
welding
power
manual.
are
clean and
are
clean and
tight.
*Replace fuse.
No wire feed.
Fuse Fl open.
Erratic wire feed.
Loose connections.
Ensure all weld cable connections
tight.
ARC
CONTROL
connec-
Ensure all connections
are
clean and
tight.
tions loose.
Control relay CR1 not func-
Watch
ing welding.
tioning properly.
necessary.
Wire retracts into gun when
trying to strike an arc.
POLARITY switch in wrong
Ensure that weld output connections and the
position.
tion of the POLARITY switch
Motor
runs too
Motor
after
arc
slowly dur-
continues
is broken.
to
run
Control relay CR1
tioning properly.
not
func-
Watch
relay
relay
as
as
power is
power is
applied. Replace CR1 if
posi
correspond.
applied. Replace CR1
if
necessary.
*If it becomes necessary to replace the fuse in the control/feeder,
and size is used.
ensure
that
a
fuse of the proper rating, type,
1
REMOTE INCH
VOLT METER
(OPTIONAL)
(OPTIONAL)
PLG1
GAS
CONTROL
(OPT IONAL)
TO WELDER
OUTPUT
Circuit Diagram No. A-046 727-
Figure 7-1. Circuit Diagram
OM-1534 Page 11
February 1980
FORM OM-1534
Effective With Serial No. J ~381O51
MODEL
S-42GL
PARTS
LIST
10
0
10
0
I
In
I-
I-
I-
I
0
I-
E
4
C
a,
U.
0
Ca.
=
~u)
0.~
OM-1 534 Page 1
Item
Dia.
Part
No.
Mkgs.
No.
Description
Main
Figure A
1
058 427
2
601 884
3
605941
Assembly
1
RING, retaining spool
NUT, hex-jam5/8-1i
-
1
6
WASHER,fIat4l/64IDx1OD
010 233 SPRING, compression
057 971 WASHER, flat keyed 1-1/2 dia
010191 WASHER,fibre5/8IDxl-1/2ODxl/8
7
058 628
8
056416
4
5
-
12
13
600 323
14
600 741
10
PB1
11
S2
-
17
CABLE, weld copper stranded No. 3/0 (order by ft)
TERMINAL, ring tongue 1/4 stud 3/0 wire
046 626 TRAY, tool
039 047 TERMINAL, power output red (consisting of)
601 879
NUT, hex-full 1/2-13
18
039044
.BUS BAR
19
20
601 880
.
15
16
1
1
1
2
2
WASHER, brake
REEL(FigCPg5)
058428 HUB, spool
047 681 SWITCH, magnetic blowout
011 611 SWITCH,toggleDPDTl5ampl25volts
004214 BUSHING,snapl-5/8IDx2
9
Quantty
-
-
-
1
1
1
1
1
4 ft
1
1
1
1
.
21
053 032
039 049
22
601 976
23
24
601 944
047 838
25
047 758
26
+046 893
27
047 917
28
R2
046 894
29
R3
073 336
604537
30
31
32
.
33
Ri
34
Ml
1
1
NUT, hex-jam 1/2-13
CLIP, spring bus bar
1
-
.
.
1
TERMINAL BOARD
hex hd 1/2-13
1-1/2
SCREW, cap
SCREW, cap-hexhd5/16-18x3/4
BLANK, snap in 1.000 hole
SWITCH, magnetic blowout (Fig B Pg 4)
HARDWARE, mounting resistor
PANEL, side
RESISTOR, WW fixed 400 watt 4 ohm
RESISTOR, WWfixed300watt8 ohm
NUT, hex-fuIl5/16-18
-
.
x
-
-
-
1
10
1
1
1
1
1
10
602211
10
073 311
2
WASHER,Iock-split5/16
CASTER, rubber-stationary 3 in
046 835 RHEOSTAT, WW300watt4 ohm
048 005 MOTOR, gear 1/12 hp 32 volts dc 2000
045 613
.
080 282
.
*045612
1
rpm (consisting of)
COVER, brush
SPRING, brush
1
2
.2
.BRUSH
2
35
057 357
BUSHING,snapi5/i6lDl.l2mountinghole
2
36
010 144
CLAMP, nylon7/l6dia
1
37
079624
39
SCREW,cap-hexhd3/8-16x2
602213 WASHER, Iock-split3/8
010910 WASHER,flat-SAE3/8
40
075 150
WASHER,
41
047 936
BASE
1
42
073 310
CASTER, rubber-swivel3 in
2
43
000527
44
605 441
45
600 848
46
601 222
47
010 610
48
.604 550
49
50
Figure D
BLANK,snap-in7/8hd61/64hdOD
TUBING, plastic 1/4 ID x 3/8 OD (order by ft)
WIRE, motor-stranded 12 ga (order byft)
CLAMP, 50 amp
CONNECTOR, clamp cable 1/2 inch
HOSE, neoprene No.1 x3/16 (order byft)
WIRE DRIVE & GEARS (Pg 6) (consisting of)
FITTING, hose barbed nipple 3/16 TBG
51
52
WASHER,nylon7/l6IDxlODxl/16
058 112 BUSHING,flanged-nylon5/16IDx7/16ODx3/4
600 742 TERMINAL, ring tongue 3/8 stud No. 3/0 wire
38
53
079 633
nylon-shielded0.622x1
1
2
3
x3/8
-
1
2
1 ft
16 f
1
1
3 ft
-
.
079619
-
2
2
1
OM-1 534
Page 2
Item
Dia.
Part
No.
Mkgs.
No.
Figure
A
Main
54
Quantity
Assembly (Contd.)
601 872
1
079 635
1
NUT, hex-fuII3/8-16
INSULATOR, motor
019 602 KNOB, pointer-rheostat
*012 655 FUSE, miniature-glassloamp25o volts
046 432 HOLDER, fuse
55
56
57
58
NAMEPLATE (order
59
*Recommended
+
Description
1
1
1
by model & serial number)
1
Spare Parts.
Part No. includes all hardware for
mounting (1) resistor.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Dia.
Part
Mkgs.
No.
Description
Parts For
Fl
*012 643
046 432
GS1
003 538
+003 539
GS1
080 841
+080 872
PB5O
047 681
045 434
045 433
045 429
010 476
11
045 468
V
025 637
045 455
056 851
010 606
604 550
056 112
045 481
073 690
007 826
048 282
079 534
025 212
010 604
602 958
000 434
057 357
Quantity
Optional Equipment
FUSE, miniature-glassslo-blol amp
HOLDER, fuse panel mounting
VALVE, 2 way 1/4 IPS port 1/8 orifice (consisting of)
COIL, 115 voltsac (Control Co.)
VALVE, 2 way 1/4 IPS port 1/8 orifice (consisting of)
COIL, 115 volts ac (Eemco)
SWITCH, magnetic blowout
CHASSIS, switch remote inch control
WRAPPER, remote inch control
CORD, interconnecting switch/control
BUSHING, strain relief 5/8 x 0.570 hole
TRANSFORMER, control
METER, volt dc 0-50 scale
HOSE, gas 16 inch (consisting of)
FITTING, hose-brass barbed nipple3/16TBG
1
1
-
or
.
1
1
1
.
-
-
-
-
-
1
1
1
1
1
1
1
1
1
.
FITTING, hose-brass nut5/8-18 RH
HOSE, neopreneNo.1x3/16 ID
FITTING, hose-brassferrule.475IDx23/32
CORD, power control (consisting of)
CAP, straight grounded 2P3W 15 amp 125 volts
CORD, No. 183/c (order by ft)
RECEPTACLE W/SOCKETS (consisting of)
TERMINAL, female 1 socket;
.
1
1
.
.
-
-
.
.
1
1
1
18 ft
1
4
.
MOUNTING PAD, solenoid
FITTING, hose brass bushing 1/4 NPT x 5/8-18 RH
FITTING, brass barbed M 1/4 TBG x 1/4 NPT
1
FITTING, gas
1
BUSHING,snapl5/161D1.l2mountinghole
1
-
-
*Recommended Spare Parts.
+ When ordering coils be sure to
provide
manufacturers
name.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 3
1
1
1
Item
Dia.
Part
No.
Mkgs
No.
Quantit
Description
047 758
Switch, Magnetic
4
3
058968
079 975
047 754
4
047 757
1
Figure
B
Blowout
-
6
047 756
RING, retainer-E
O-RING,3/l6lDxO.103
PIN, hinge
COVER, top switch actuator
SWITCH, magnetic blowout
BRACKET, mounting switch
7
047 755
SUPPORT-CABLE
2
5
CR1
047 680
(Fig
A
Pg 2
Item 25)
2
2
-
1
-
1
-
3
7
TA-045 404
Figure B
-
Switch, Magnetic
-
Blowout
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1534
F~age4
Item
Part
No.
No.
Figure C056 416
Description
Quantity
Reel, Wire (Fig A Pg 2 Item 8)
1
604 051
NUT,wingl/2-13
2
056312
3
056313
4
010224
5
601 880
FINGER, reel
STUD, 1/2-13 x7 inches
PIN, spring 3/16 xl inch
NUT, hex-jam 1/2-13
6
056314
REEL
7
010910
8
601 964
WASHER, flat SAE 3/8
SCREW, cap hex hd 3/8-16
4
4
4
4
4
-
-
x
3/4
3
4
5
6
TC-056 416
Figure C
-
Reel, Wire
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
Page 5
Item
Part
No.
No.
Figure
Description
Wire Drive & Gears
D
1
045 396
2
601 925
3
010224
4
047 969
5
010232
A
(Fig
Pg 2 Item 49)
(consisting of)
WIRE DRIVE
6
602 243
7
056 306
8
010231
9
010910
10
604590
11
13
079669
079634
604741
14
604538
SCREW, cap hex hd 1/4-20 x 1/2
PIN, spring compression 3/16-1
HOUSING, adapter gun/feeder
SPRING, compression
WASHER, fIat 3/8
FASTENER, pinned
SPRING, compression
WASHER, flat-SAE3/8
NUT, wing 3/8-16
LEVER, mounting pressure gear
PIN, hinge
PIN, cotter- hair0.042 x 15/16
WASHER, flat- SAE5/16 (as reqd)
15
079772
KNOB
16
079625
17
053841
18
079626
19
20
000418
602 241
21
605518
22
053 842
12
Quant ty
-
-
-
1
1
-
1
1
1
1
WASHER, spring 1/2 shakeproof (as reqd)
GEAR, spur insulated w/key
SCREW, machine-fillisterhdlo-32x7/8
SCREW, cap hex hd 1/2-20 x 1/2 self locking
WASHER, flat SAE 1/4
SCREW, cap hex hd 1/4-20 x 1-1/4
GEAR, spur insulated w/ bearing
1
1
-
6
1
-
1
-
-
-
14 & 15
For Drive Roll And W
Guide Kits See Page
re
21
TC-047 870
Figure
D
-
Wire Drive & Gears
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1 534 P ge 6
NOTE
Base selection of drive rolls upon the
1.
following recommended
usages:
U-Groove rolls for soft and soft shelled cored wires.
2. U-Cog rolls for extremely soft shelled wires (usually hard surfacing types).
3. Split V-Knurled rolls or hard shelled cored wires (self-shielding and CO2 shielded types).
4. Drive roll types may be mixed to suit particular requirements (example: V-knurled roll in combination
with
U-groove).
Wire Diameter &
Fraction
Decimal
Type
Kit No.*
Metric
Roll Drive
inlet Wire
Part No.
Type
Guide
1/16
.062
1.6MM
079601
053706
U-groove
056195
5/64
.079
2.0MM
079 602
053 704
U-groove
056 195
3/32
.094
2.4MM
079 603
053 703
U-groove
056 196
7/64
.110
2.8MM
079 604
053 705
U-groove
056 196
1/8
.126
3.2MM
079 605
053 707
U-groove
056 197
1/16
.062
1.6MM
079609
056771
V-knurled
056 195
5/64
.079
2.0MM
079 610
056 773
V-knurled
056 195
056196
3/32
094
2.4MM
079611
056774
V-knurled
7/64
.110
2.8MM
079612
056775
V-knurled
056196
1/8
.126
3.2MM
079 613
056 776
V-knurled
056 197
1/16
.062
1.6MM
079614
053708
U-cogged
056195
056195
5/64
.079
2.0MM
079615
053710
U-cogged
3/32
.094
2.4MM
079 616
053 709
U-cogged
056 196
7/64
.110
2.8MM
079 617
053711
U-cogged
056 196
1/8
.126
3.2MM
079618
053712
U-cogged
056197
Drive Roll & Wire Guide Kits
When
ordering replacement parts all kits listed with the exception of the V-KNURLED kits are
are required for the one piece drive kits and four drive rolls for.the split V-knurled kits.
drive rolls
See Section 36 inOwneisManual for identification of parts.
Page
7
one
piece drive rolls. Two
Part
No.
Description
Common Hardware
602 086
604 804
602 109
601 925
602 154
601 954
605 518
601 939
079 620
005 715
602 200
602 203
602 241
602 207
601 860
601 861
601 862
601 865
SCREW, machine round hd 8-32 x 1
SCREW, sheet metal hexagonal washer hd No. 8 x 3/8
SCREW, machine round hd 10-24 x 1/2
SCREW, cap hex hd 1/4-20 x 1/2
SCREW, self tapping hexagonal washer hd 1/4-20 x 1/2
SCREW, cap hex hd 1/4-20 x 3/4
SCREW, cap hex hd 1/4-20 x 1-1/4
SCREW, cap hex hd 1/4-28 x 1-1/2
SCREW, cap flat hd 1/4-28 x 1/2
BOLT, carriage 1/4-20 x 1
WASHER, lock split No. 8
WASHER, lock split No. 10
WASHER, flat SAE 1/4
WASHER, lock split 1/4
NUT, hex machine screw 8-32
NUT, hex machine screw 10-24
NUT, hex machine screw 10-32
NUT, hex full 1/4-20
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-1534
Pige8