advertisement
T M 9 - 3 4 3 1 - 2 5 8 - 1 4 & P
T E C H N I C A L M A N U A L
O P E R A T O R ’ S , O R G A N I Z A T I O N A L , D I R E C T S U P P O R T
A N D G E N E R A L S U P P O R T M A I N T E N A N C E
M A N U A L I N C L U D I N G R E P A I R P A R T S L I S T
F O R
T O R C H O U T F I T , W E L D I N G , G A S
M O D E L 1 3 7
( N S N 3 4 3 1 - 0 0 - 6 9 1 - 1 4 1 5 )
T h i s c o p y i s a r e p r i n t w h i c h i n c l u d e s c u r r e n t p a g e s f r o m C h a n g e 1
.
H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y
31 JULY 1981
Change
No. 1
Changes in force: C1
O P E R A T O R ’ S , O R G A N I Z A T I O N A L , D I R E C T S U P P O R T
A N D G E N E R A L S U P P O R T M A I N T E N A N C E M A N U A L
I N C L U D I N G R E P A I R P A R T S L I S T
F O R
T O R C H O U T F I T , W E L D I N G , G A S
M O D E L 1 3 7
( N S N 3 4 3 1 - 0 0 - 6 9 1 - 1 4 1 5 )
T M 9 - 3 4 3 1 - 2 5 8 - 1 4 & P
C 1
H E A D Q U A R T E R S
D E P A R T M E N T O F T H E A R M Y
Washington, DC, 20 March 1985
TM 9-3431-258-14&P, 31 July 1981, is changed as follows:
Page i.
U n d e r “ R E P O R T I N G O F E R R O R S ” , c h a n g e m a i l i n g a d d r e s s t o : C o m m a n d e r , U S A r m y A r m a ment, Munitions and Chemical Command, ATTN: AMSMC-MAS, Rock Island, IL
61299-6000.
Page 3. The part number chart is rescinded. Add new part number charts as follows:
Wire Wire
T ype Size
(In.)
Front Guide Bushing
Part No.
N S N
Rear Guide Bushing
Part No.
N S N
Aluminum 0.020
2220A338H04
0.030 220A338H04
3/64
1/16
220A338H06
220A338H05 3431-00-126-8947
Mild &
Stainless
Steel
0.020 220A338H04
0.030 220A338H04
0.035 220A338H04
488A441H02
488A441H02
488A441H01
488A441H01
488A441H02
488A441H02
488A441H02
5365-00-166-8500
5365-00-166-8500
1
TM 9-3431-258-14&P
Wire
Type
Wire
Size
(In.)
Part No.
Drive Roll
NSN
Aluminum 0.020 419A009G3 3431-00-160-7879
0.030 419A009G03 3431-00-160-7879
3/64
1/16
419A009G01
419A009G01
3431-00-875-7633
3431-00-875-7633
Mild &
Stainless
Steel
0.020
0.030
0.035
419A009G03
419A009G03
419A009G01
3431-00-160-7879
3431-00-160-7879
3431-00-875-7633
Part No.
Guide Tube
NSN
306B172H01
306B172H01
306B172H09
306B172H10
306B172H01
306B172H03
306B172H04
3431-00446-2644
Nozzle
Wire
Type
Aluminum
Mild &
Stainless
Steel
Wire
Size
(In.)
0.020
0.030
3/64
1/16
0.020
0.030
0.035
Part No.
311B703H03
311B703H03
311B703H02
311B703H02
311B703H03
311B703H03
311B703H02
Page 14. Add the following NSNs to the parts list:
Ref. No.
1
3
9
10
Add NSN
5355-00-246-3925
3431-00-164-2666
5905-00-161-3447
3431-00-446-2643
NSN
3431-00-446-2642
3431-00-446-2642
3431-00-446-2642
2
Ref. No.
14
34
35
22
23
27
29
15
19
20
Page 15. Add the following NSNs to the parts list:
Ref. No.
37
47
48
57
58
59
60
Page 29. Add the following NSNs to the parts list:
Ref. No.
1
10
22
Add NSN
3431-00-875-7638
3431-00-875-3977
3431-00-875-3977
5315-00-175-7467
5360-00-175-2907
3110-00-409-3279
5365-00-166-8500
3431-00-875-7646
3431-00-875-7635
3431-00-163-0180
Add NSN
3431-00-446-2637
3431-00-875-7641
5365-00-173-0055
3431-00-446-2642
3431-00-446-2644
3431-00-875-7633
6105-00-169-6189
Add NSN
5930-00-132-2672
6150-01-045-1260
5945-00-875-7889
TM 9-3431-258-14&P
3
By Order of the Secretary of the Army:
JOHN A. WICKHAM, JR.
General, United States Army
Chief of Staff
Official:
DONALD J. DELANDRO
Brigadier General, United States Army
The Adjutant General
D I S T R I B U T I O N :
To be distributed in accordance with DA Form 12–21 requirements for FSC
Group 3431-IL.
Technical Manual
No. 9-3431-258-14&P
TM 9-3431-258-14&P
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, DC, 31 July 1981
OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT
AND GENERAL SUPPORT MAINTENANCE
MANUAL INCLUDING REPAIR PARTS LIST
FOR
TORCH OUTFIT, WELDING, GAS
MODEL 137
(NSN 3431-00-691-1415)
I
REPORTING OF ERRORS
You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028
(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2, located in the back of this manual direct to: Commander, US Army Armament
Materiel Readiness Command, ATTN: DRSAR-MAS, Rock Island, IL 61299.
A reply will be furnished directly to you.
NOTE
This manual is published for the purpose of identifying an authorized commercial manual for the use of the personnel to whom this welding set is issued.
Manufactured by: Westinghouse Electric Corp.
Industrial Electric Div.
P.O Box 300
Sykesville, MD 21784
Procured under Contract No. DAAA09-79-C-2019
L
This technical manual is an authentication of the manufacturers’ commercial literature and does not conform with the format and content specified in AR 310-3,
Military Publications. This technical manual does, however, contain available information that is essential to the operation and maintenance of the equipment.
i/(ii blank)
INSTRUCTIONS FOR REQUISITIONING PARTS
NOT IDENTIFIED BY NSN ldhe~ requisitioning parts mandatory that the follow net identified by National Stock Number, it is ng information be furnished the supPly officer.
1Manufacturer’s Federal Supply Cod6 Number - 0$452
2Manufacturer’s Part Number exactly as listed herein.
3Nomenclature exactly as listed herein, including dimensions, if necessary.
4Manufacturer’s Model Number Model 137
5Manufacturer’s Serial Number (End Item)
6Any other information such as Type, Frame Number, and Electrical
Characteristics, if applicable.
7[f DO Form 1348 is used, fill in all blocks except 4, 5, 6, and
Remarks field in accordance with AR 725-50.
Ccmplete Form as Follows:
(a) In blocks 4. S, 6, list manufacturer’s Federal Supply Code
Number - 08452 followed by a colon and manufacturer’s
Part Number for the repair part.
(b) Complete Remarks field as follows:
Noun: (nomenclature of repair part)
For: NSN: 3431-00-691-1415
Manufacturer: Westinghouse Electric Corp.
Model:
Serial:
137
(of end item)
Any other pertinent information such as Frame Number,
Type, Dimensions, etc.
INTRODUCTION
DESCRIPTION .
The SP WELDING GUN
INSTALLATION . . . . . . .
GAS CONNECTIONS .
LOCATIONS . . . .
WELDING CURRENT CONNECTIONS
GUN CONTROL CONNECTIONS . . .
OPTIONAL PARTS REQUIRED FOR VARIOUS WIRE SIZES
OPERATION . . . . . . . . .
SAFETY PRECAUTIONS
GUIDE TUBE POSITION
WIRE THREADING . .
BRAKE ADJUSTMENT .
WELDING SETUP . .
WELDING TECHNIQUES
NOZZLE SPACING .
GUN ANGLE . . . .
CLEANNESS OF MATERIAL
WIRE CLEANERS
MAINTENANCE . . . . . . . . .
OPERATING MAINTENANCE
REPLACEMENT PARTS .
ILLUSTRATIONS
SP-9 and SP-10 OUTLINE
WIRING DIAGRAM . . . .
SCHEMATIC . . . . . . .
DRAWING
TYPE CCD-4 CONTROL
ILLUSTRATIONS
Outline
Schematic
Wiring Diagram
483A756
655C951
483A767
2214A57
720B096
221C688
PAGE
INTRODUCTION
The SP-9 and SP-10 Welding Gun is intended for use as part of a complete package for control of gas shielded consumable metal arc welding.
The package includes the SP-9 or SP-10 Gun and the CV-2 Control when used with a constant potential welder.
When arc spot welding is to be performed with a constant voltage welder, the CVS-2 Control and the CVAS-2 Timer is used.
The guns may be used with a constant current DC Welder when the CC-2 Control is used.
The WCP-1 Welder, a constant potential welder with a built-in gun control, may also be used with these guns.
DESCRIPTION
The SP Welding Gun
Type SP-9 Welding Gun is designed for use with 1/16-inch to 3/64-inch diameter aluminum welding wire on one-pound spools, 0.035-inch to 3/64-inch diameter Type MS
21 mild steel welding wire on 1-1/2 pound spools, and 0.035-inch to 3/64-inch diameter stainless steel welding wire on one-pound Spools.
It can also be used with
10-pound spools of 3/64-inch diameter aluminum wire.
The SP-10 Welding Gun is designed for use with 0.020-inch and 0.030-inch diameter aluminum welding wire on one-pound spools, 0.020-inch to 0.030-inch diameter Type
MS-21 mild steel welding wire on 1-1/2 pound spools, and 0.020-inch to 0.030-inch diameter stainless steel welding wire on one pound spools.
The Welding Gun SP-9 and SP-10 are compact, light-weight units designed to give dependable service over an extended period.
All exposed parts of the gun are fully insulated from welding voltage for operator safety and prevention of accidental shorts.
The distribution of weight and the cable and hose arrangement give excellent balance which make the welding guns easy to handle in all positions. The total weight of either welding gun (including a one-pound wire spool) is less than four pounds.
Each welding gun consists primarily of a gun barrel housing with a removable tapered nozzle, a mounting bracket with a shielding gas valve operated by the trigger, a handle of high impact plastic which contains the wire drive motor, a protective shield with electrode speed control, a plastic reel cover, a control cable, a welding current cable, and a gas hose.
The tapered nozzle (Part 1 on Drawing 483A756) is held by a nozzle holder (2) which is threaded to the gun barrel housing (3). A copper guide tube (4) passes thru the gun barrel and is secured by a thumbscrew (5). Mounted within the mounting bracket are a front guide bushing (6) and a rear guide bushing (7).
The mounting bracket also includes a ball type shielding gas valve operated by the trigger (8) through a plunger. The trigger also actuates the weld switch (9). Pivoted on the side of the mounting bracket is a swing arm (10) on which is mounted an idler roll (11).
DESCRIPTION
The SP Weldinq Gun - Continued
The swing arm is secured in the closed position by a pressure screw (12) and a pressure spring (13). A, 50-foot control cable (14) extends from the base of the handle, and has a plug for connection to the control.
A protective shield (15) is secured to the mounting bracket and includes the electrode speed control (16).
A four-inch diameter spool of welding electrode (17) is mounted on the spool shaft supported by the shield.
A plastic cover (18) is secured to the spool shaft supported by the shield.
A plastic cover” (18) Is secured to the spool shaft by a knurled thumbscrew.
The combination of protective shield and plastic cover completely enclose the welding wire spool and provide protection against spatter or other foreign matter.
The plastic cover also enables the operator to see the quantity of welding wire remaining the spool.
An adjustable spool brake (19) is secured to the protective shield, and bears against the wire spool to prevent uncoiling of the weldlng wire.
In operation, the welding electrode from the spool passes thru the rear guide bushing, between the drive and idler roll, thru the front guide bushing, and thru the guide tube.
The wfre then passes thru the nozzle to the arc.
Welding current is transmitted thru the current cable to the gun barrel and to the guide bar, which in turn, ing current to the welding wire.
When the weld trigger is squeezed, the motor is energized to feed the welding wire to the arc and the gas valve shielding gas to the arc area.
transmits weldwlre drive opens to supply
NOTE : Inching circuit not included in CV-2 Control.
Inch button will operate when this gun is used with CVS-2 or CC-2 Control.
INSTALLATION
Immediately after opening the carton, make a careful examination of the contents to ensure that no damage has occurred during shipment.
Do not discard any packing without first accounting for all small parts such as guide tubes. If any shortage or damage is discovered or suspected, promptly file a claim with the carrier and notify the nearest
Sales Office.
Gas Connections
Gas is supplied to the welding gun thru the gas hose which must be connected thru a regulator and flowmeter to the shielding gas supply.
Location
The ideal location for this welding equipment is a clean, dry place where the temperature does not exceed 40°C. (104°F.).
Under these conditions, the system can be expected to give excellent performance with a minimum of maintenance.
- 2 -
Wires &
Sizes
Aluminum
Mild &
Stainless
Steel
0.020
0.030
3/64
1/16
0.020
0.030
0.035
Front Guide
Bushing
220A338H04
220A338H04
220A338H06
220A338H05
220A338H04
220A338H04
220A338H04
INSTALLATION
Welding Current Connections
Welding current is supplied from the welder to the welding gun through the gun current cable (21 of Drawing 483A756).
This cable should be connected to the Electrode
(Positive) terminal on the welder.
Also, connect a #2 or larger welding cable from the Work (Negative) terminal to the work ground.
Gun Control Connections
Plug the control cable (14 of Drawing 483A756) into the gun control receptacle on the control, making sure that the plug is fully engaged.
Optional Parts Required for Various Wire Sizes
Depending upon the size of the welding wire used, optional parts for the welding gun may be required.
These parts are listed below with the corresponding welding wire sizes.
Insure that the welding gun is equipped with the correct part.
Rear Guide
Bushing
488A441H02
488A441H02
488A441H01
488A441H01
488A441H02
488A441H02
488A441H02
Drive Roll
419AO09G03
419AO09G03
419AO09G01
419AO09G01
419AO09G03
419AO09G03
Guide Tube
306B172H01
306B172H03
306B172H09
306B172H1O
306B172H01
306B172H03
306B172H04
Nozzle
311B703H03
311B703H03
311B703H02
311B703H02
311B703H03
311B703H03
311B703H02
NOTES: The SP-9 Gun as shipped is equipped for 3/64-inch wire.
The SP-10 Gun as shipped is equipped for 0.030-inch wire.
OPERATION
Safety Precautions
Inert-gas, metal-arc weldinq processes Produce intense ultra-violet radiation which can be harmful to the eyes and skin.
Therefore, certain precautions must be observed to protect the operator from injury.
Eye and face protection should be accomplished with a welding helmet which has a #10 or
#12 shade welding plate.
In addition, the operator should wear #2 shade flash goggles beneath the helmet.
Skin must be completely covered.
Leather gloves are recommended
Safety Precautions - Continued for hand protection.
Heavy, dark-colored clothing should be worn to prevent the radiation penetrating to the skin or reflecting onto the neck under the helmet. Light weight leather clothing Is recommended because of its durability and resistance to deterioration from radiation.
Cotton clothing will deteriorate rapidly when subjected to ultra-violet radiation.
Adequate ventilation should be provided to remove fumes which are produced by this welding process.
American Standard Z-49.1 on welding safety covers such ventilation procedures.
Highly toxic gases are formed when the vapors from halogenated solvents are subjected to ultra-violet radiation.
Therefore, It is recommended that degreasers and other sources of these vapors should be located so that the vapors cannot reach the welding operation.
Detailed safety precautions are given In the American Welding Society’s publication
A6.1-55T, “Recommended Safe Practices for Inert-Gas Metal-Arc Welding”.
GuideTube Position
Loosen the thumbscrew (5), and adjust the position of the guide tube until the end of the guide tube is 1/8-inch behind the edge of the nozzle.
When using 0.020 and
0.030-inch wires, the rear end of the guide tube must be back against the front guide tube bushing to prevent the wire from buckling. With the rear end of an .020
or .030 guide tube (in the SP-10 Gun) positioned against the guide bushing, the front end will be just even or slightly in front of the nozzle.
Wire Threading
Unscrew the knurled spool cover bolt, and remove the plastic cover. Pull back the adjustable brake (19), and place the desired spool of welding wire on the spool shaft so that the free end of the wire will pay off from the top of the spool into the rear guide bushing (7).
Loosen the wire pressure screw (12) and open the swing arm (10).
Thread the free end of the wire Into the rear guide bushing, thru the front guide bushing (6), and Into the wire guide tube (4).
Close the swing arm (10) and adjust the pressure screw until there is just sufficient pressure to prevent the wire from slipping.
Excessive pressure will overload the motor and cause erratic welding action.
Too little pressure will allow slippage and cause burn backs . Switcn the welder on and pull the gun trigger (8).
Since welding power still will be on when the trigger is pulled, make sure the electrode does not touch the work ground as an arc will result.
If the wire has been threaded properly and the pressure screw is adjusted for the correct pressure, the wire will feed freely from the guide tube. -
Brake Adjustment
Loosen the two screws support by moving the wire spool to prevent which hold the brake support.
Adjust the position of the brake screw in the slotted hole. Just enough pressure is applied to the the wire from uncoiling.
OPERATION
Welding Setup
The following data is intended as a starting point in arriving at the proper adjustment of the system for welding an aluminum joint.
It is important to understand that the final adjustment for a particular joint may vary considerably from this data depending on weld position, fit up material thickness, fillet size, etc.
1.
Set the voltage control on the welder at the applicable voltage setting:
GUN WIRE SIZE VOLTAGE SETTING
SP-9
SP-9
SP-10
3/64 Inch
1/16-Inch
0.030-Inch
23 Volts
28 Volts
20 volts
NOTE : The open circuit voltage is usually about one to two volts higher per 100 amperes of welding current than the arc voltage.
2. Loosen the pressure screw (12) and release the swing arm (10) to move the idler roll out of position.
Taking care not to touch the work piece with wire, squeeze and hold the weld trigger; at the same time, adjust the gas regulator to give the required gas flow.
As a starting point, adjust the gas flow to 35 cubic feet/hr.
An increase or decrease may be required after welding conditions have been established.
Reclose the swing arm and readjust the pressure screw.
3.
Adjust the position of wire so that the free end protrudes 1/2-inch to 3/4-inch beyond the end of the nozzle.
4.
Turn the electrode feed speed control to the maximum setting.
5. With the electrode near the work, but not touching, lower the head shield, squeeze the trigger, and bring the electrode into contact.with the work piece to strike an arc.
6.
Reduce the electrode feed speed control setting until the stubbing ceases and the crackling sound of the arc just disappears.
When the setting of the electrode feed speed control is increased, the weld current is increased.
7.
To stop the weld, release the trigger and draw the welding gun away from the work.
Do NOT whip the gun away from the work without first releasing the trigger to
TO BREAK the arc.
Failure to observe this precaution may result in: a.
Loss of the gas shield before the weld pool freezes, causing porosity.
b. Too much wire will extend from the nozzle at the end of the weld requiring a clipping operation before the next weld.
c.
Extremely high transient voltages can develop which may damage the motor.
OPERATION
Welding Techniques
After the operator has found the desired current, voltage, and electrode feed speed settings for a particular application, it is still necessary to observe some elementtary principles of technique.
1.
2.
3.
4.
Nozzle Spacing -
In general, the gas nozzle should be held as close to the work as is practical.
In most cases, a distance of 3/8-inch to 5/8-inch is satisfactory.
Gun Angle -
The best cleaning action is obtained, and excellent porosity-free welds are made by using a forehand technique. For example, a horizontal fillet is best made by the welding gun at an angle of 40° to 50° to the horizontal and using a forehand angle of 20° to 25°.
A right-handed operator would then weld from right to left on a horizontal weld.
Cleanness of Material -
It is essential that aluminum be absolutely clean when it is welded. To ensure porosity-free welds, a cleaning operation should immediately precede the welding operation.
Several organic solvents are now available for this purpose.
Wire Cleanness -
Wire should be clean and free from oxide, grease, and other foreign material. Do not try to use wire that is not clean.
Wire which is not in use should be kept in a container which will protect it from all forms of contamination.
MAINTENANCE
Operating Maintenance -
As the gun is used, a small amount of spatter will collect on the end of the guide tube and on the nozzle.
This spatter can be removed easily with a knife or similar implement.
Periodically, remove the nozzle by pulling it from the nozzle holder and inspect the nozzle and gun barrel for spatter which may have collected inside.
Excessive spatter can cause a short between the nozzle and the guide tube. Such a short will create an arc between the nozzle and the workpiece if accidental contact is made.
If the guide tube becomes bent, replace it with a new guide tube.
If a burn back occurs, do not inch the wire.
Attempts to inch the wire under these circumstances will blow the fuses in the control circuit.
When a burn back occurs, loosen the thumbscrew which secures the guide tube, and inch both the wire and the guide tube out of the gun.
Cut the wire about 1/16” from the rear of the guide tube.
Hold the guide tube perpendicular to a hard, flat surface, and strike the end of the wire against the flat surface.
If this does not free the wire, cut or grind off the melted portion of the guide tube and remove the wire.
The burr caused by cutting should be removed from the guide tube hole with a small drill.
Failure to remove the burr can result in another burn back. Reinstall the guide tube in the gun, ensuring that the end of the guide tube is the correct
MAINTENANCE
Operating Maintenance - Continued distance from the nozzle.
The 1/16 to 0.035-inch tubes may be trimmed a maximum of
3/8-inch, and the 0.020 to 0.030-inch tubes may be trimmed a maximum of l/8-inch before discarding.
The gas holes in the gun barrel may become clogged with a residue of white powder which will obstruct the flow of gas.
The gun should be dismantled every 100 hours, and the gas holes blown out with high pressure air.
REPLACEMENT PARTS
Reference should be made to the Renewal Parts List for identification of replacement parts.
Renewal Parts Data
RENEWAL PARTS DATA
TYPE SP-10 GUN
STYLE #483B128G02
11
RENEWAL PARTS DATA
26
27
28
29
30
21
22
23
24
25
31
32
33
34
35
11
12
13
14
15
6
7
8
9
10
16
17
18
19
20
THE FOLLOWING PARTS ARE MOST SUBJECT TO WEAR IN
ORDINARY OPERATION:
COMMON PARTS
REF. NO.
DESCRIPTION OR NAME OF PART
1
2
3
4
5
KNOB FOR RHEOSTAT
SHIELD
REEL SHAFT
REEL COVER
REEL COVER BOLT
O RING
RUBBER BUSHING
POT. SHIELD
DUAL POT. ASSY
BRAKE
BRAKE SUPPORT
INSULATOR *
ADAPTER
INSULATING WASHER
INSULATING WASHER
GUN BARREL HOUSING
GUN BARREL INSULATION
GUN BARREL ASSEMBLY
FRONT GUIDE BUSHING 1/16 & 3/64
PIN
PIPE PLUG
SPRING
BALL BEARING
MTG. BRACKET
FITTING ASSEMBLY
FITTING
REAR GUIDE (.035 TO 1/16)
INSULATING WASHER
NYLON SCREW
INSULATED IDLER ROLL
BEARING ARM
SPRING
BEARING ARM BOLT
INSULATED GUIDE TUBE LOCK SCREW
HANDLE ASSEMBLY (INCLUDES BOTH LEFT AND
RIGHT HANDLE HALVES)
IDENTIFICATION NUMBER
451A240H01
867D652G01
448A024H01
637C247H01
419A029H01
576D964H07
363A421H90
483A753H01
483A752H01
419A011H01
419A008H01
222A550H01
419A003H01
419A006H02
419A006H01
453A483H01
419A005H02
419A002G02
2209A70H01
452A107H01
2209A69H01
452A106H01
452A108H01
427C605G08
427C605G04
419A043H01
488A441H01
310B141H04
442A169H01
557D415H39
419A026H02
419A027H01
419A025H01
422A505G01
827D099G03
1
1
1
1
1
1
1
1
1
2
3
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
NUMBER
PER UNIT
1
1
1
1
1
14
RENEWAL PARTS DATA
46
47
48
49
50
41
42
43
44
45
51
52
53
54
55
56
57
58
59
60
36
37
38
39
40
THE FOLLOWING PARTS ARE MOST SUBJECT TO WEAR IN
ORDINARY OPERATION.
COMMON PARTS
REF. NO.
DESCRIPTION OR NAME OF PART
NUMBER
IDENTIFICATION NUMBER PER UNIT
SWITCH TRIGGER
SPRING FLAT
SPRING
TRIGGER ASSEMBLY
CAPACITOR
301B663H05
205A091H01
453A464H01
451A241G01
422A518H04
1
1
1
1
1
KNIFE DISCONNECT
SWITCH
GAS HOSE ASSEMBLY
CURRENT CABLE ASSEMBLY
POWER SUPPLY CABLE ASSEMBLY
PLUG
BOOT
RETAINING RING *
BUSHING, CORD PROTECTOR
COPPER STRAP *
INSULATION
TUBING
TUBING
PLUG BUTTON *
PLUG BUTTON *
INSULATION
NOZZLE
GUIDE TUBE
DRIVE ROLL
MOTOR
429C550H10
301B663H09
1474B90G01
1474B91G01
1112C77G07
483A890H01
419A046H01
52D9290H01
2214A61H01
576D964H64
419A010H02
422A484H01
422A484H02
451A237H02
451A237H03
453A434H01
311B703H02
306B172H09
419A009G01
429C550G05
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
2
1
1
WIRING DIAGRAM
* NOT SHOWN
655C951
15
DESCRIPTION INSTALLATION OPERATION MAINTENANCE
Instruction Book
TYPE CCD-4 CONTROL
The CCD-4 Control is designed for consumable electrode inert-gas shielding welding with the SP-9 or SI?-10 gun.
It incorporates a well-balanced hand-gun and a control with a built in contactor. The system is designed for semi-automatic welding of aluminum with aluminum wire sizes from .030 to 1/16 inch diameters , and for steel wire siz’es of
.030 to 3/64 inch diameters.
DESCRIPTION
The Control as shown on Outline Drawing 2214A57 is lightweight, properly insulated, and compact. (Numbers in parentheses indicate item numbers on referenced drawings.)
The_Control operates from a 115 volt A.C.
or D.C. power supply required for tile operation of the co~trol and inching circuits.
The power for the gear-head drive motor during the welding operation is supplied by the welding machine.
The motor armature is said to be across the arc , This is accomplished by attaching the terminal of the ground cord (4) to the negative lug of the welder and the terminal of’ the current cable (12) to the positive lug of the welder.
The control cable for the welding gun is coxmected to the Gun Control Receptacle (1) and the welding current cable of the gun inserts into the Receptacle (5).
A rheostat in the welding gun is adjusted to control the wire feed speed and the arc length.
The rheostat setting will vary with the t-ype of shielding gas used and with different welding machines, and is primarily dependent on the current setting of the welder. The fact that the wire feed drive opera,tes from the arc voltage is important, because it insures good steady feeding consistent with constant arc length.
It is based on the following principle of operation: If the arc length increases, the voltage across the arc becomes higher and increases the motor speed, thereby feeding more wire and shortening the arc length.
shortens,
If the arc length the voltage across it is lower and the motor speed decreases, thereby i~creasing the arc l-ength.
approximately a 6 to 1 speed range.
The rheostat type control works through
An On-Off switch (2) energizes the control monitor while replaceable fuzes (6) protect the line.
The power supply cord (3) is a 16 foot cable terminated in a three-prong plug with a three to two wire plug adapter.
A replaceable fuze (7) in series with the wire drive motor protects the armature from damage due to high current.
should not be replaced with a larger fUZe.
This is a one ampere fUZe and
The line fUZeS (6) shoul.dbe 2 atnperefuzes.
The Control Monitor has a current relay which permits touch starts. The normal minimum current required to operate the relay is approximately 45 amperes. A 200 amp D.C.
contactor (9) is mounted in the control enclosure and is controlled from the control panel (8).
1 7
INSTALLATION
Receivinq
Immediately upon receipt of the equipment, make a careful examination for evidence of damage encountered in transit.
If any damage is found or suspected, file a claim promptly with the transportation company and notify the nearest sales office.
Do not discard any packing materiel without first checking it for small accessory items.
Location
The control should be installed so that all parts of the workpiece to be welded can be reached with a minimum of effort.
Approximately 50 feet of cable and hose. are normally supplied with the gun. The control unit should be located so no sharp kinks or bends are made in the gas hose. Care should be taken to avoid dragging the cable or hose over hot work or sharp projections.
The distance from the welding machine to the control is not critical and is limited only if the voltage drop due to the length and size of the cable prevents stable welding conditions.
The 115 volt suppuly cable maybe extended as required, within reasonable limits.
It is usually best if the control is placed as close to the workpiece as is practical, therefore making it easy for the operator to make adjustments or reenergize the equipment as required.
Connections
1 .
Attach the Regulator and Flowmeter to a cylinder of pure argon by threading nut on regulator-flowmeter to matching threads on cylinder.
Tighten the nut to prevent gas leaks.
The gas cylinder is not part of.
welding set.
2.
Attach nut on gas hose from welding gun to the matching threads on the outlet side of regulator-flowmeter and tighten to prevent gas leakage.
3.
As shipped, the SP-9 or SP-10 welding gun has a terminal on the end of the welding cable.
Remove this terminal and add the camlock plug ineluded with the CCD-4 Control. Insert the plug into the matching receptacle on the control. ‘this plug is keyed and must be rotated to the proper position before inserting.
After inserting plug, turn plug 1/4 turn clockwise to lock in place.
4
0
Insert plug on end of control cable from welding gun in matching receptacle on the control monitor.
This plug is also keyed and must be rotated to the proper position before inserting.
After the plug is lined up properly with receptacle, gently work plug into socket and tighten retaining ring.
18
5* Attach current cable from control monitor to the positive (+) output
~ermina,l of the welding power SUpply.
This cable includes a large terminal for connection to the positive (+) output terminal. Since this weliiing set may be used tith various types of welding power supplies, some adaptation to make this connection may be required. HOW ever, a tight connection is required.
include a polarity stitch,
On welding power supplies which this cable should be attached to the terminal marked electrode and the polarity switch should be placed in the Reverse Polarity position.
Be certain that any high voltage or high frequency arc starters are kept deactivated.
6.
Attach one end of a ground cable and the ground cord from the control monitor to the negative terminal of the welding power supply.
must be a ti&t connection.
This
On welding power supplies with a polarity switch, these leads are connected to the Work terminal.
should be tight amd electrically conducting.
Connections
7* Connect the other end of the ground cable to the workpiece or material to be welded.
This must be a tight connection with good electrical conductiv~ty.
8, Connect the line cord to a 110 to 125 volt AC or DC supply. This cord is equipped with a standard 3-prong plug.
supply, an adapter is provided.
For connection to a 2-prong
Where used, the screw on the side of the adapter should be conneeted to the frame of the welding machine with a short piece of wire.
OPERATION
Welding
1.
Adjust the current control on the welder to the required output current.
2* To adjust the gas flow, first turn on the gas supply by turning on the main valve at the top of the gas cylinder.
Being careful not to touch the wire to the workpiece, pull the weld trigger and hold; at the same time adjust the gas regulator by turning the flow adjustment to the required gas flow. As a starting point adjust the flow to 35 cubic feet/ hour.
This is indicated when the top of the ball in the flow reaches the calibration marked 35.
An increase or decrease may be required after welding conditions are established.
3* Adjust the position of the wire to protrude 1/2 to 3/4 of an inch beyond the end of the nozzle by pressing the inch button.
4. Turn the rheostat knob (16) on the welding gun to maximum.
1 9
Welding+ (cent)
5.
With the wire near the work, but not touching, lower the head shield, pull the veld trigger and bring the wire into contact with the workpiece. M arc will form and the wire will begin to feed.
6.
With the wire feed speed knob on the control monitor adjusted near maximum as described in paragraph 4, the arc will probably be too short and the wire will stub, causing considerable spatter.
Decrease the setting of the wire feed control until the proper arc length is accomplished.
This is usually the point where the crackling sound of the arc just disappears.
With this welding control system, the dial setting affects axc length by changing electrode wire feed speed at a given welding power supply current setting.
Increasing the setting of the dial will. shorten the arc.
7* To stop the weld, release the trigger.
Do not whip the gun aw ay from the work before releasing the trigger to break the arc as this will cause excessive wire stick-out.
High Frequency Precautions
The control monitor should never be connected to a welder at the same time the welder is being used on high frequency as the motor will burn-out instantly.
Neither the ground clamp nor the electrode lead should ever connect to a welder which is supplying welding current and high frequency to a tungsten arc torch or any other prccess requiring high frequency.
SAFETY PRECAUTIONS
Inert-gas metal-arc welding processes produce intense visible and ultraviolet radiation smd require certain precautions to protect the operator from injury.
For eye protection, welding helmets should have a #10 or #12 shade welding plate.
In addition, the operator should wear #2 shade flash goggles with wide side shields under the helmet.
The skin should be completely covered.
Leather gloves are recommended for hand protection. Heavy, dark-colored clothing should be worn to prevent radiation from penetrating to the skin or from reflecting onto the neck under the hood.
Lightweight leather protective clothing is also recommended because of its durability and resistance to deterioration from the radiation and sparks. It shouldbe noted that cotton clothing is subject to rather rapid deterioration.
Adequate ventilation should be provided to remove fumes produced by the process, as set forth in American Standard Z-49.1 on safety in welding.
Inas much as vapors from halogenated solvents such as trichloroethylene are decompose3by ultra-violet light to form highly toxic gases, it is recommended that degreasers or other sources of such vapors be so located that the vapors will not reach the welding operation.
2 0
Safety Precautions (cont)
Detailed safety practices are given in the publication A6.1-55T on
“Recommended Safe Practices for Inert-Gas Metal-Arc Welding”, published by the American Welding Society.
2 1
Renewal Parts Data
Type CCD-4 Control
Style 483B126G05
Renewal Parts
25
26
28
RENEWAL PARTS
21
22
23
24
25
16
17
18
19
20
11
12
13
14
15
6
7
8
9
10
26
27
28
29
COMMON PARTS
REF. NO.
DESCRIPTION OR NAME OF PART
1
2
3
4
5
ON-OFF SWITCH
NAMEPLATE
HANDLE
GUN CONTROL RECEPTACLE
FUSES (2 AMP)
FUSE (1 AMP)
RECEPTACLE
CABLE ASSY (GROUND)
CABLE ASSY
CABLE ASSY (CURRENT)
TERMINAL BOARD
RESISTOR (5R) 10 OHM, 25W
RESISTOR (1R) 100 OHM, 100W
RESISTOR (2R) 25 OHM, 25W
RESISTOR (4R) 1K, 20W
CONTACTOR
STRAIN RELIEF
STRAIN RELIEF
STRAIN RELIEF
RELAY (2CR) 3PDT
CAPACITOR (3C, 4C) .047 MFD
RELAY (3CR)
CAPACITOR (2C)
RECTIFIER ASSY (1RX)
CAPACITOR MOUNTING CLAMP
CAPACITOR (5C) 4 MFD
RESISTOR (3R)
RELAY (4CR) DPDT
FUSE HOLDERS
SCHEMATIC DIAGRAM
WIRING DIAGRAM
IDENTIFICATION NUMBER
429A051H02
228P758H01
1129648
483A891H01
363A018H16
363A018H15
419A012H01
432C524G12
2222A01G01
1474B91G02
32B1029H15
363A014H46
422A473H02
422A473H06
363A114H88
2224A77H01
582D430H06
576D916H73
427C613H04
480B096H27
363A104H86
320B224G01
2224A78H01
2224A79H01
474A830H01
2224A78H02
474A023H01
480B096H26
2218A11H01
720B096
221C688
2
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
NUMBER
PER UNIT
1
1
1
1
2
29
30
31
3 2
33 (34 blank)
By Order of the Secretary of the Army:
Official:
B. G. JOYCE
Brigadier General, United States Army
The Adjutant General
DISTRIBUTION:
To be distributed in accordance with Special List.
E. C. MEYER
General. United States Army
Chief of Staff
* U.S. GOVERNMENT PRINTING OFFICE: 1995 -388-421/00349
THE METRIC SYSTEM AND EQUIVALENTS
P I N : N 0 4 9 3 3 2 - 0 0 1 2 - 0 0 0
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