Owner`s Manual SGA 100 And SGA 100C NOTE NOTE

Owner’s Manual
SGA 100 And SGA 100C
1.
October 2001
FORM: OM-190 753H
Use above FORM number when ordering extra manuals.
Safety Symbol Definitions
Warning! Watch Out! There are possible hazards as
shown in the adjoining symbols.
Have only trained and qualified persons install, operate,
or service this unit. Call your distributor if you do not understand the directions. For WELDING SAFETY and
EMF information, read welding power source Owner’s
Manual.
Beware of electric shock from wiring. Turn Off welding
power source and disconnect power before installing this
kit. Reinstall all panels and covers.
Hot parts can cause burns. Welding makes parts very hot
– let them cool before touching.
Wear safety glasses with side shields.
NOTE
2.
The SGA 100 and SGA 100C are not required for use with the Millermatic 185,
Millermatic 210, and IronMan 210 models, and IronMan 250 models effective with
serial no. LA135884 and following).
Weld Control Specifications
Specification
Input Power
Single-Phase 115 Volts AC, .5 Amperes, 60 Hertz
Control Circuit Voltage Provided To Spool Gun
36 Volts DC
Welding Power Source Type
Constant Voltage (CV) DC, With or Without Contactor
Connections
Gun Trigger Controls, Gas And Weld Cables
Welding Process
DC Gas Metal Arc Welding (GMAW)
Input Power Cord With Plug
10 ft (3 m)
Overall Dimensions
SGA 100: 13 in (330 mm) L x 8 in (203 mm) W x 5 in (127 mm) H
SGA 100C: 13 in (330 mm) L x 8 in (203 mm) W x 9 in (229 mm) H
Weight
SGA 100: 10 lb (4.5 kg); SGA 100 C: 13 lb (5.9 kg)
3.
Duty Cycle
Maximum rating for the SGA 100
and SGA 100C is 150 amperes at a
60% duty cycle.
6 Minutes Welding
NOTE
4 Minutes Resting
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If you are connecting this spoolgun adapter to a unit with an output
contactor, proceed to Section 4. If you are connecting this spoolgun
adapter to a unit without an output contactor, proceed to Section 5.
 2001 MILLER Electric Mfg. Co.
4.
Installing SGA 100 Spoolmate Adapter (Kit 043 856)
A. Making Connections To Units With An Output Contactor (Millermatic 185, Millermatic 210, And IronMan
210 Models, And IronMan 250 Models Effective With Serial No. LA135884 And Following Do Not Require
This Accessory)
.Drawing shows typical welding
.100% argon shielding gas
power source installation.
required for aluminum.
1
9
11
2
.Loosen and raise drive tension arm
on power source wire feeder, and
turn off mild steel shielding gas
supply when using spool gun.
12
3
8
10
5
6
7
7
4
Tools Needed:
8
3/4 in
Y Turn Off and disconnect input
power.
1 Spoolmate Spoolgun
2 SGA 100 Control Box
3 Welding Power Source With 1/2 in
(13 mm) Weld Cable Stud
4 1/2 in (13 mm) Weld Cable Stud
5 Front Panel
6 Front Panel Opening
7 Spoolgun Weld Cable
Route Spoolgun weld cable through front
panel opening and connect to 1/2 in (13
mm) weld cable stud. NOTE: if unit does
not have a 1/2 in (13 mm) weld cable stud,
proceed to Section 3B
8
Interconnecting Cord
9
Spoolgun Gas Hose
Slide spoolgun gas hose onto barbed fitting
on SGA 100 control box where shown.
10 Spoolgun Trigger Control Plug
Connect interconnecting cord as shown.
NOTE: a second interconnecting cord with
female friction terminals on each end (not
shown) is provided with this kit. If your unit
requires this type of interconnecting cord
for trigger operation, connect female
friction terminals to matching male friction
terminals on welding power source and
SGA 100 control box. Polarity is not
important.
Connect spoolgun trigger control plug to
matching receptacle on SGA 100 control
box where shown.
11 Gas Hose
Slide gas hose onto fitting on back of SGA
100 control box.
12 115 VAC Plug
Connect plug as shown.
Ref. 802 181
OM-190 753 Page 2
B. Connecting Spoolmate Spoolgun Weld Cable To Units Without A 1/2 in Weld Cable Stud
.Drawing shows typical welding
1
2
3
power source installation.
Wire Drive Assembly
Gun Securing Bolt
Gun Securing Nut
Remove gun securing nut.
4
Terminal
Slide terminal onto gun securing bolt
and secure with gun securing nut.
5
Spoolgun Weld Cable Ring
Terminal
Cut off ring terminal and strip insulation back 1/2 in (13 mm).
Slide spoolgun weld cable into terminal 1/2 in (13 mm). Tighten setscrew.
2
Go back to Section 3A, Item 8, to
complete the installation.
4
1/2 in
3
5
Tools Needed:
1
5/16 in
Ref. 802 181
OM-190 753 Page 3
5.
Installing SGA 100C Spoolmate Adapter w/ Contactor (Kit 043 857)
A. Making Connections To Units Without An Output Contactor
Y Turn Off and disconnect input power or shut off engine.
.Drawing shows typical welding
power source installation.
1
2
3
4
5
Welding Generator
Weld Cable (Customer
Supplied)
Spoolmate Spoolgun
Spoolgun Weld Cable
SGA 100C Control Box
Proceed to Section 4B
6
Spoolgun Gas Hose
Slide spoolgun gas hose onto
barbed fitting on SGA 100C control
box where shown.
7
Spoolgun Trigger Control Plug
Connect spoolgun trigger control
plug to matching receptacle on
SGA 100C control box where
shown.
1
8
Gas Hose
Slide gas hose onto fitting on back
of SGA 100C control box.
9
115 VAC Plug
Connect plug to 115 volt power supply.
8
9
2
3
Or
9
4
6
5
7
802 188
OM-190 753 Page 4
B. Making Connections In The Contactor Control Box
.The SGA
100C can be used
with MIG welding power
sources by simply following the
hookup procedure for an SGA
100.
Tools Needed:
3/8 in
3
1
2
1
SGA 100C Control Box
Contactor Box
Remove contactor box
6
3
4
Contactor Control Leads
Spoolgun Weld Cable Ring
Terminal
Cut off ring terminal and strip insulation back 1/2 in (13 mm).
1/2 in
5
Terminals
Slide spoolgun weld cable into terminal 1/2 in (13 mm). Tighten setscrew.
6
Weld Cable
Strip insulation back 1/2 in (13 mm).
2
Slide weld cable into terminal 1/2 in
(13 mm). Tighten set-screw.
1/2 in
Install contactor box back onto
SGA 100C control box.
Go back to Section 4A, Item 6 to
complete this installation.
5
4
Ref. 802 189-A
Model
SGA 100 w/3035 spool
gun on Millermatic 135
SGA 100 w/3035 spool
gun on Millermatic 135
SGA 100 w/3035 spool
gun on Millermatic 175
SGA 100 w/3035 spool
gun on Millermatic 175
Wire Size / Type
.030 / 4043
.035 / 4043
.030 / 4043
.035 / 4043
Metal Size
Wire Feed Speed Setting
Voltage %
14 ga aluminum
25 – 30
65 – 85
1/8 in aluminum
25 – 30
100
3/16 in aluminum
—
—
1/4 in aluminum
—
—
14 ga aluminum
25 – 30
80 – 100
1/8 in aluminum
25 – 30
100
3/16 in aluminum
—
—
1/4 in aluminum
—
—
14 ga aluminum
35 – 40
35 – 40
1/8 in aluminum
45 – 50
45 – 50
3/16 in aluminum
50 – 55
80 – 100
1/4 in aluminum
50 – 55
80 – 100
14 ga aluminum
28 – 32
35 – 40
1/8 in aluminum
38 – 42
45 – 50
3/16 in aluminum
40 – 45
100
1/4 in aluminum
40 – 45
100
.These values are starting parameters only. When welding aluminum use 100% argon shielding gas, maintain a 1/2 to 3/4 in tip to work distance,
and a 10 to 15 degree push angle with the spool gun.
OM-190 753 Page 5
6.
Electrical Diagram
Figure 6-1. Circuit Diagram
OM-190 753 Page 6
206 578
Notes
OM-190 753 Page 7
7.
Parts
3
4
2
1
5
6
7
24
8
9
21
20
19
23
10
18
22
11
17
12
16
15
14
13
802 302-A
Figure 7-1. Main Assembly
OM-190 753 Page 8
Quantity
Kit
Part
No.
1 ......
2 ......
3 ......
4 ......
5 ......
6 ......
7 ......
8 ......
9 ......
10 . . . . .
11 . . . . .
12 . . . . .
13 . . . . .
14 . . . . .
15 . . . . .
16 . . . . .
17 . . . . .
18 . . . . .
18 . . . . .
19 . . . . .
20 . . . . .
21 . . . . .
22 . . . . .
23 . . . . .
23 . . . . .
24 . . . . .
........
........
........
057 357
190 421
190 418
131 515
190 525
206 951
170 970
195 531
206 960
114 050
072 817
048 282
134 201
191 345
184 734
172 171
097 924
206 815
206 816
206 949
198 087
206 582
190 420
025 338
024 376
191 103
190 681
190 682
183 581
043856
043857
Description
SGA 100 Spoolmate Adapter Kit 043 856 Or
SGA 100C Spoolmate Adapter w/Contactor Kit 043 857
. . . . . . . . . . . . . BUSHING, snap-in nyl .937 ID x 1.125 mtg hole . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . COVER, ext contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . W . . CONTACTOR, def prp 40A 3P 120 VAC coil . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . T1 . . XFMR, control 115V pri 35V/24V sec . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . GS1 . . VALVE, 115 VAC 2way 2 pipes 6mm 60 Hz . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . CB1 . . CIRCUIT BREAKER, man reset 1P 2.5A 250V . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . CABLE, power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . R2 . . RESISTOR, ww fxd 10W 1K ohm . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . CR1 . . RELAY, encl 24 VAC DPDT 20A/120 VAC 8 pin fla . . . . . . . . . 1 . . . . . . . .
. . . . . RC2 . . RECEPTACLE w/skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . STAND-OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . .
. . . . . . . . . . . . . FOOT, mtg snap-in vinyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . .
. . . . . . . . . . . . . BUSHING, terminal 2 position . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . FTG, hose brs barbed coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . KNOB pointer 1.625 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . R1 . . POTENTIOMETER, cp std slot 1T 2W 1K linear . . . . . . . . . . . 1 . . . . . . . .
. . . . . PC1 . . CIRCUIT CARD ASSY, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . BUSHING, nyl univ 23/32 hd dia .625 mtg hole . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . BLANK, snap-in nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . LUG, univ w/scr 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . CABLE, interconnecting 6 ft trigger fric to fric . . . . . . . . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . CABLE, interconnecting 6 ft trigger (amp) 4 pin to fric . . . . . . . 1 . . . . . . . .
. . . . . . . . . . . . . HOSE, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . .
2
1
1
1
1
1
1
1
1
1
1
1
4
3
1
1
1
1
1
1
1
1
1
2
1
1
1
OM-190 753 Page 9
OM-190 753 Page 10