Miller AUTO ARC 255 Owner’s Manual

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Miller AUTO ARC 255 Owner’s Manual | Manualzz
November 1997
Form:
OM-157 066H
Effective With Serial No. KH51 1668
Support, Contact:
Inc., National Distributor
Box 338, Hortonville, WI 54944-0338
For Technical
Milweld
P.O.
Tel 920-779-0924 Fax 920-779-0924
OWNERS
MANUAL
Auto Arcfi Model 255
Wire Welder
Rated
200 A
Welding Output
Amperage
Range DC
Maximum
Open-Circuit
Voltage DC
Amperes Input at Rated Load
Output, 50 or 60 Hz, Single-Phase
230 V
KVA
KW
46
40
1.1*
1.3*
9.5
0.31*
8.3
0.18*
200 V
@ 28 Volts DC, 60%
Duty Cycle
40250
42
250A@28VottsDC,40%
Duty Cycle
Wire
Type
And Diameter
Solid Steel /
Stainless Steel
Flux Cored /
Aluminum
Wire Feed
Speed Range
.
.023
(0.6
.045 in
1.2
mm)
.030
.035 in
mm) And
(0.8 0.9
3/64 in (1.2 mm)
90
1030 1PM
(2.9
-26.2
rn/mm)
Overall Dimensions
Length:
Width: 19 in
(940 mm)
(483 mm)
Alu
Height:
~While
37 in
32 in
Weight
225 lb
(102 kg)
(889 mm)
idling
auto arc 6/95
ST-157 072-A
PRINTED IN USA
Warranty
Etteclive January 1, 1907
with
serial number preface of 10
a
(Equipment
This limited warranty supersedes all previous manufacturers
warranties and is exclusive with no other guarantees or
Limited
warranties
1.
expressed
implied.
or
Warranty
Items furnished
others, such
LIMITED WARRANTY
below,
warrants to
Subject
original
its
to the terms and conditions
items
retail
any.
purchaser that
new
after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
are
or
newer)
shall not
apply
to:
by manufacturer, but manufactured by
as
engines or trade accessories. These
by the manufacturers warranty, if
covered
equipment sold
shipped
from
OF
LIEU
factory.
OTHER
ALL
Consumable components; such as contact tips, cutting
nozzles, contactors, relays, brushes, slip rings, or parts
2.
THIS WARRANTY IS EXPRESSLY IN
EXPRESS
WARRANTIES,
WARRANTIES
INCLUDING
THE
MERCHANTABILITY AND FITNESS.
that fail due to normal
OR
wear.
OF
IMPLIED,
Within the
that has been modified by any party other
manufacturer, or equipment that has been
improperly installed, improperly operated or misused
based upon industry standards, orequipment which has
not had reasonable and necessary maintenance, or
Manufacturer must be notified in writing within thirty (30) days
of such defect or failure, at which time manufacturer will
provide instructions on the warranty claim procedures to be
the
Equipment
3.
than
warranty periods listed below, manufacturer will
repair or replace any warranted parts or components that fail
defects in material
due to such
or
workmanship.
followed.
Manufacturer shall
honor
warranty claims
on
warranted
equipment listed below in the event of such afailure within the
warranty time periods. All warranty time periods start on the
date that the equipment was delivered to the original retail
purchaser, or one year after the equipment is sent to the
5 Years Parts
3 Years Labor
warranty claim covered by this warranty,
*
Plasma Arc
Semi-Automatic and Automatic Wire Feeders
*
Robots
compensation
*
Engine
3 Years
Parts and Labor
*
Transformer/Rectifier Power Sources
Power Sources
Cutting
Driven Welding Generators
(NOTE: Engines are warranted separately
or reimbursement for transportation costs of
any kind will be allowed.
by
the
1 Year
Parts and Labor
(wlexception
of
Spoolmate 185)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
Orbital Weld Heads
Water Coolant
Systems
HF Units
Grids
*
Spot
*
Load Banks
*
SDX Transformers
*
*
Welders
Running Gear/Trailers
Options
(NOTE: Field options are covered under the limited
warranty far the remaining warranty period of the
product they are installed in, or for a minimum of one
whichever is greater.)
year
Field
6 Months
Batteries
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MANUFACTURER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL
OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS
WARRANTY NOT PROVIDED HEREIN
IMPLIED
WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
MIGHT
ARISE
BY
PROVISION,
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT
FURNISHED
BY MANUFACTURER IS
AND
ANY
EXCLUDED AND DISCLAIMED BY MANUFACTURER.
Some states in the U.S.A. do not allow limitations of how
90
Days
Parts and Labor
limitation
available,
or
exclusion may not
MIG Guns/TIG Torches
In
*
Plasma
additional
*
*
*
*
Torches
Remote Controls
Accessory Kits
Replacement Parts
Spoolmate 185
to you. This
and other rights
apply
warranty
may be
but may vary from state to state.
Canada, legislation in
*
Cutting
long
implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
an
provides specific legal rights,
5.
the
of
main power rectifiers
Motor Driven Guns
4.
a
*
Original
engine manufacturer.)
3.
In the event of
repair or replacement at an authorized service station; or
(4) payment of or credit for the purchase price (less
reasonable depreciation based upon actual use) upon return
of the goods at customers risk and expense. manufacturers
option of repair or replacement will be FOB., Factory at
Appleton, Wisconsin, or FOB. at an authorized service
facility as determined by manufacturer. Therefore no
*
2.
MANUFACTURERS
PRODUCTS ARE INTENDED FOR
PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL
USERS AND PERSONS TRAINED AND EXPERIENCED IN
USE
WELDING
THE
AND
MAINTENANCE
OF
EQUIPMENT.
exclusive remedies shall be, at manufacturers option: (1)
repair; or (2) replacement; or, where authorized in writing by
manufacturer in appropriate cases, (3) the reasonable cost
distributor,
1.
equipment which has been used for operation outside of
specifications for the equipment.
some
provinces provides for certain
other than as stated
may not be waived, the
limitations and exclusions set Out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
herein,
warranties
or
remedies
and to the extent that
they
province.
brand_warr 5/97
SECTION 1
OM-157 066G
1-1.
-
SAFETY PRECAUTIONS FOR ARC WELDING
safety_somi 4/95
3/97
Symbol Usage
AA
Warning! Watch Out! There
procedure! The possible hazards are
Means
I
possible
hazards with this
shown in the
adjoining symbols.
are
Marks
A
a
special safety message.
~ Means NOTE; not
related.
safety
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary
actions to avoid the hazards.
1-2.
Arc
Welding
Hazards
WARNING
a
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The
safety information given below is only a summary of the more complete safety information found in the
Safety Standards listed in Section 1-4. Read and follow all Safety Standards.
persons should install, operate, maintain, and
Only qualified
During operation, keep everybody, especially children
ELECTRIC SHOCK
can
terminal in disconnect box
5.
6.
8.
9.
10. Do not
Always verify
cord
supply ground
sure
that
input
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Noise from some
can
damage hearing.
processes
grinding, and welds cooling throw off
metal or slag.
Chipping,
pieces of
NOISE
Use
with
I
I
~
ear
plugs
or ear
muffs if noise level is
FUMES
AND
GASES
hazardous to your health.
Keep
17.
exhaust at the
4.
If ventilation is poor,
be
safety
is
workpiece
do not
Clamp
harness if
use
or
working
and
covers
cable
with
panels
work
2.
Wear
required, ground it directly
clamp or work cable.
work
worktable
replace
manual.
above floor level.
securely
in
place.
metal-to-metal
good
as near
or
the weld
contact
to
łractical.
as
a
welding
helmet fitted with
a
proper shade of filter to
or watching (see ANSI
protect your face and eyes when welding
Z49.1 and Z87.1 listed in
3.
4.
Wear
Use
protective
and
glare;
Wear
Safety Standards).
approved safety glasses
screens or
with side shields.
barriers to
protect
others not to watch the
warn
others from flash
arc.
protective clothing made from durable, flame-resistant
(wool and leather) and foot protection.
5.
Work in
only if it is well ventilated, or while
air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
a
wearing
arc
confined space
an
Do not weld in locations
operations.
form highly
to
approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDS5) and the
manufacturers instruction for metals, consumables, coatings,
cleaners, and degreasers.
use an
poorly spliced
material
remove
3.
or
ARC RAYS
your head out of the fumes. Do not breathe the fumes,
use
Keep
a
all
workpiece
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
If inside, ventilate the area and/or
welding fumes and gases.
grounding
your body.
over
of the
separate cable
a
15. Wear
high.
can
damaged, undersized,
only well-maintained equipment. Repair
damaged parts at once. Maintain unit according to
6.
2.
worn,
14. Use
5.
approved
proper
13. Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
around wire is orooerlv connected to around
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
~
1.
use
Owners
check and be
attach
cables.
16.
the
a
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Turn off all equipment when not in use.
grounding
Manual and national, state, and local codes.
is connected to
plug
outlet.
double-check connections.
drape cables
parts.
that cord
making input connections,
conductor first
12. If earth
oower
1.
When
11. Do not
Do not touch live electrical
Wear
4.
7.
dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 191 0.147 (see Safety Standards).
Properly install and ground this equipment according to its
1.
or
properly grounded receptacle
live
2.
3.
this unit.
away.
kill.
electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In
semiautomatic or automatic wire welding, the wire,
wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live.
Incorrectly installed or improperly grounded
equipment is a hazard.
Touching
repair
7.
Do not weld
cadmium
near
degreasing, cleaning,
The heat and rays of the arc
toxic and irritating gases.
on
coated metals, such
plated steel,
weld area, the
area
unless the
is well
can
as
coating
or
spraying
react with vapors to
galvanized, lead,
or
is removed from the
ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-157 066
Page
1
CYLINDERS
if
explode
can
4.
damaged.
5.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be
1.
2.
3.
sure
to treat them
6.
7.
carefully.
Protect
8.
mechanical shocks,
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical
9.
in
WELDING
Welding
can
fire
cause
or
on
closed
containers, such
connected for
associated
use.
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
can
sure
the
area
that
8.
sparks, explosion, overheating,
can cause
fire. Check and be
fire, and keep
Be
7.
hot
and burns. Accidental contact of electrode to metal
or
Watch for
is safe before
doing any welding.
9.
1.
Protect
2.
Do not weld where
yourself
and others from
flying sparks
flying sparks
can
and hot metal.
10.
strike flammable material.
Remove all flammables within 35 ft
(10.7 m) of the welding arc. If
possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
11.
this is not
Additional Installation,
Do not locate unit on, over,
1.
12.
Do not weld
1.
2.
near
Keep away
Keep away
injure
flammables.
1.
FALLING
EQUIPMENT
can
cause
serious personal injury and equipment
tanks, drums,
lifting eye
gas
cylinders,
to lift unit
or
or
can cause
from
moving parts.
from
pinch points
injury.
such
as
drive rolls.
NOT
only,
or
DIRT
can
eyes.
Wear
safety glasses
WIRE
WELDING
Use
partition
with side shields
or
face
shield.
damage.
1.
as
FLYING PIECES OF METAL
Do not install unit
or
or near
surfaces.
2.
closed containers such
MOVING PARTS
near
or
extinguisher nearby.
ceiling, floor, bulkhead,
the hidden side.
on
on
fire
a
on a
pipes, unless they are properly prepared according to AWS F4. 1
(see Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
result from
can
unit
over,
on,
combustible surfaces.
placing
fire
welding
And Maintenance Hazards
Operation,
FIRE OR EXPLOSION
aware
can cause
or pipes, can cause them to blow up. Sparks
fly off from the welding arc. The flying sparks,
workpiece, and hot equipment can cause fires
oblects
5.
6.
tanks,
as
drums,
1-3.
use or
a
a
Standards.
explosion.
4.
drape
10. Read and follow instructions
circuits.
3.
welding torch over a gas cylinder.
welding electrode to touch any cylinder.
Never weld on a pressurized cylinder
explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in placeover valve except when cylinder is
Never
Never allow
can
cause
puncture
wounds.
running gear,
any other accessories.
equipment of adequate capacity to lift unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
Use
1.
Do not press gun
2.
Do not
trigger
until instructed to do
so.
point gun toward any part of the body, other
people, or any metal when threading welding wire.
unit.
HOT PARTS
can cause severe
HIGH-FREQUENCY
interfere with radio
burns.
Do not touch hot parts bare handed.
Allow
cooling period before working
on
gun
services,
or
1.
MOVING PARTS
can cause
Keep away from moving parts
Keep all doors, panels, covers,
and securely in place.
1.
2.
injury.
such
and
as
fans.
guards
~~Jj,J
2.
FIELDS
can
FROM
affect
closed
HIGH
pacemaker
Pacemaker
arc
OM-157 066
Page
2
with
responsible for having a qualified
promptly correct any interference
problem resulting from the installation.
If notified
4.
Have
the
by the FCC about interference, stop
equipment at once.
the
installation
regularly
checked
and
maintained.
wearers
keep away.
5.
Wearers should consult their doctor before
near
familiar
installation.
is
user
using
operation.
operations.
only qualified persons
electronic equipment perform this
electrician
3.
MAGNETIC
CURRENTS
equipment.
Have
The
can
and
computers,
communications
torch.
RADIATION
navigation, safety
welding, gouging,
or
going
spot welding
Keep high-frequency source doors and panels
tightly shut, keep spark gaps at correct setting,
and use grounding and shielding to minimize the
possibility of interference.
OVERUSE
can
OVERHEATED
cause
SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters.
EQUIPMENT.
1.
Allow
2.
Reduce
cooling period.
starting
current
or
1.
duty cycle before
reduce
again.
duty cycle.
touching
on
or
wrist
parts.
static-proof bags
ship PC boards.
move,
1-4.
or
in
American
Safety
1.
and boxes to store,
Welding and Cutting, ANSI Standard Z49.1, from
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 NW. LeJeune Rd, Miami, FL 33126
National Electrical
Code, NFPA Standard 70, from National Fire
Batterymarch Park, Quincy, MA 02269.
Protection Association,
to
before
Section
any parts.
Shut off
shielding gas supply when
harm
can
not in use.
Safe
Handling of Compressed
Gases in
Cylinders,
CGA
Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard Wil 7.2,
Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
from
Safe Practices For Occupation And Educational Eye And Face
from American National
ANSI Standard Z87.1
Protection,
Standards Institute, 1430
Broadway,
New
York, NY 10018.
Cutting
Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park, Quincy,
And
MA 02269.
EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
The
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): ... there is now a very
large volume of scientific findings based on experiments at the
To reduce
cellular level and from studies with animals and
people which clearly
frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is of
very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
potential risks.
cables close
1.
Keep
2.
Arrange
3.
Do not coil
4.
Keep welding
practical.
power
source
5.
Connect work
clamp
to
establish that low
avoid
magnetic fields in the workplace,
use
the
following
procedures:
of the U.S.
or
and
Principal Safety Standards
Safety
1-5.
Maintenance
BUILDUP OF SHIELDING GAS
health or kill.
strap BEFORE handling
Use proper
in
input power,
according
damage parts
-
boards
grounded
capacitors
input
instructions
STATIC ELECTRICITY can
on circuit boards.
Put
discharge
to weld
Follow rated
Turn Off inverter, disconnect
cables to
or
together by twisting
one
taping
side and away from the
cables around the
drape
or
as
operator.
body.
and cables
workpiece
them.
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The above
wearers.
procedures
are
also recommended for
Consult your doctor for
pacemaker
complete information.
OM-157 066
Page
3
SECTION 2- INSTALLATION
2-1.
Installing
Work
Clamp
1
Work Cable
2
Boot
Slide boot onto work cable. Route
cable out front panel opening from
inside.
Negative () Output
3
Terminal
Connect cable to terminal
cover connection with boot.
and
5
4
Hardware
5
Work
Clamp
Route cable
and
2
through clamp
secure as
handle
shown.
Close door.
Tools Needed:
~==:::~ 1/2,3/4
in
ST-800 918-B
2-2.
Installing Gas Supply
Chain gas
wall,
or
cylinder to running gear,
stationary support so
other
cylinder
cannot fall and break off
valve.
1
Regulator/Flow Gauge
Install
2
so
face is vertical.
Gas Hose Connection
Fitting
has
5/8-18
right-hand
threads.
3
Flow
Adjust
flow rate is 20 cfh
feet per hour). Check wire
Typical
ufacturers
rate. This
adjusted
4
Argon Gas
ORQ
man
recommended
flow
gauge
flow
can
be
between 5 and 25 cfh.
CO2 Adapter
Customer
5
(cubic
Supplied
0-Ring
Install adapter with 0-ring between
regulator/flow gauge and CO2
cylinder.
Tools Needed:
~=~=r 5/8,1-1/8in
ST-i 54 623-A / Ret. ST-i 09492
OM-157 066
Page
4
2-3.
Installing Welding Gun
1
Drive
2
Gun
3
Gun End
Assembly
Securing Knob
Loosen
securing knob. Insert gun
through opening until it bot
toms
against drive assembly.
Tighten nut.
end
4
Gun
Trigger Plug
Insert
plug
tighten
threaded collar.
into
receptacle,
and
Close door.
Ref. ST-801 677
2-4.
Installing
Wire
Spool
And
Adjusting
Hub Tension
OM-157 066
Page
5
2-5.
Setting
Gun
Polarity
~~
1
~d~eE~:
Label
Assembly)
_________________________
Always
tures
Set For Electrode
Shown As Shipped
Positive (DCEP) For Solid Steel Or
Aluminum Wires (GMAW Process).
Wire Drive
To Positive
Assembly
(+) Output
Lead
Terminal
Work Clamp Lead To
Negative () Output Terminal
GUN POLARITY
CHANGEOVER CONNECTIONS
Reverse Lead Connections
For Electrode
Negative (DCEN) For Flux Cored Wires
(FCAW Process). Drive Assembly
Becomes Negative
S~144 449D
Tools Needed:
~
OM-157 066
3/4,11/161n
Page
6
read and follow manufac
recommended
polarity.
2-6.
2-7.
Positioning Jumper
Links
Electrical Service Guide
Input Voltage
Input Amperes
At Rated
Output
Max Recommended Standard Fuse Or Circuit Breaker
Rating
200
230
46
40
70
60
8
8
In
Amperes
Mm
Input
Conductor Size In AWG/Kcmil
Max Recommended
Mm
Grounding
Input
Conductor
Length
In Feet
Conductor Size In AWG/KcmiI
Reference: 1996 National Electrical Code
(Meters)
89
(27)
8
117
(36)
8
(NEC).
S-oo92J
OM-157 066
Page
7
2-8.
Selecting
A Location And
Connecting Input
Power
1
Rating
Supply
Label
correct
input
power.
2
Plug
3
Receptacle (Not Supplied)
Connect
4
plug
to
receptacle.
Line Disconnect Device
See Section 2-7.
A Special installation may be
required where gasoline or
volatile liquids are present
NEC Article 511
Section 20.
see
A
Do not
move or
where it could
operate
or
CEC
unit
tip.
A Always connect
grounding conductor first.
=
GND/PE.
4
Li
L2
2.
ST-800 923-A
OM-157066Page8
2-9.
Threading Welding
Wire
Spool
Wire
Tools Needed:
Welding
Wire
Inlet Wire Guide
4
Pressure
Adjustment
Knob
Drive Roll
Outlet Wire Guide
Gun Conduit Cable
Lay gun
Open pressure assembly.
Pull and hold wire; cut off end.
Push wire thru
cable out
guides
straight.
into gun;
continue to hold wire.
POWER
-4-8
O0~~I
Close and
assembly,
tighten pressure
and let go of wire.
Remove gun nozzle and contact
1111
Press gun
trigger
until wire
out of gun. Reinstall
contact tip and nozzle.
comes
I II
Feed wire to check drive roll pressure.
knob enough to prevent slipping.
lighten
tip.
Cut off wire. Close
and latch door.
Ref. 5T-801 677 / S-0627-A
OM-157 066
Page
9
SECTION 3- OPERATION
3-1.
Front Panel Controls
3-2.
Center Battle Controls
1
Wire Mode Switch
For better control of wire
the Low
position
speed use
when wire
speed
ipm. Use
the Full position when wire speed
is between 150 ipm and 1030 ipm.
is between 90 and 670
2
Voltage Range
Selector
Place switch in desired
position.
I~ef. ST-800919/S-171 601
OM-157 066
Page
10
3-3.
Duty Cycle
And
Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If
RATED
unit
overheats,
thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
OtJrPUT-1
300
welding.
A
~---
250
I
-
Exceeding duty cycle
damage unit and
can
void
-
I
U)
w
warranty.
~E~E~E~J !~E
200
w
150
-J
w
100
20
30
40
60
60
70
8060100
% DUTY CYCLE
60%
6 Minutes
Duty Cycle
At 200
Amperes
4 Minutes
Welding
Resting
Overheating
~AorV-,~
4
Reduce
Duty Cycle
Minutes
dutyl 4/95SB-150
OM-157 066
215
Page
11
SECTION 4- MAINTENANCE & TROUBLESHOOTING
4-1.
4-2.
Routine Maintenance
Circuit Breaker CB1
OM-157 066
Page
12
4-3.
Fuses Fl And F2
A Turn
1
Off
unit,
and
connect
input power.
Fuse Fl
(See
dis
Parts List For
Rating)
the 115 volts ac wind
of transformer Ti. If Fl opens,
all weld output stops and pilot light
Fl
protects
ing
PL1 goes out.
2
Fuse F2
(See
Parts List For
Rating)
F2 protects the 24 volts ac winding
of transformer Ti. If F2 opens, all
weld
output stops.
Toots Needed:
c::::::::J=::=il:
3/8 in
Ret. ST-8.QO 928-B
OM-157 066
Page
13
4-4.
Changing
Drive Roll And Wire Inlet Guide
Screw
1
Securing
2
Inlet Wire Guide
Loosen
drive
Slide
screw.
rolls
tip as close to
possible without
as
touching. Tighten
screw.
Anti-Wear Guide
3
Install
guide
as
shown.
Drive Roll
4
Install correct drive roll for wire size
and
type.
5
Drive Roll
Turn nut
one
Securing
click to
Nut
secure
drive
roll.
Tools Needed:
-~~~1
5/64 in
z~ 7/16 in
ST-150 227-C
4-5.
Aligning
Drive Rolls And Wire Guide
A Turn Oft unit.
View is from
ing
top of drive rolls look
down with pressure
assembly
open.
Correct
1
Drive Roll
2
Drive Roll
3
Wire Guide
4
Welding
5
Drive Gear
Securing
Nut
Wire
Incorrect
Insert screwdriver, and turn screw
or out until drive roll groove lines
in
up with wire
guide.
1
Close pressure
assembly.
5
$
Tools Needed:
Ref. ST-800 412-A
OM-157 066
Page
14
4-6.
Troubleshooting
riH*~ rn~~
Welding
No weld
output;
Trouble
wire does not feed.
Remedy
Secure power cord
plug
receptacle (see Section 2-8).
in
Reset circuit breaker CB1
Replace
fuse Fl and/or F2
Replace building
Secure gun
line fuse
trigger plug
Thermostat TP1 open
(see Section 3-3).
No weld output; wire feeds.
Connect work
Replace
Low weld
clamp
contact
(see Section 4-3).
in
receptacle
or
repair leads,
feeding stops during
replace trigger
(see Section 2-3).
switch
to metal contact.
tip (see Gun Owners Manual).
input voltage
or
check for low line
Wire Drive/Gun Trouble
Electrode wire
or
Allow fan to run; the thermostat will close when the unit has cooled
get good metal
to
(see Section 2-8).
reset circuit breaker if open
or
(overheating).
Connect unit to proper
output.
(see Section 4-2).
voltage (see Section 2-8).
Remedy
Straighten
gun cable and/or
replace damaged parts (see Gun Owners
Manual).
welding.
Adjust
drive roll pressure
Readjust
hub tension
(see
(see
contact
tip
Clean
replace
wire inlet
or
Replace drive
Secure gun
Check and
rolls if
in
(see
guide
worn or
trigger plug
replace
Section
if blocked
Replace
Section
or
2-9).
2-4).
Gun Owners
liner if
slipping (see
receptacle
Fl and/or F2
(see
or
~
Factory
or
plugged (see
Section
Section
Manual).
or
replace trigger
switch
(see Section 2-3).
4-3).
assembly
Authorized Service
Gun Owners
4-4).
repair leads,
Check and clear any restrictions at drive
Have nearest
dirty
Manual).
Agent
and liner
(see
Gun Owners
Manual).
check drive motor.
OM-157 066
Page
15
SECTION 5- ELECTRICAL DIAGRAM
For
Circuit Diagram Portion, refer
Diagram located inside the wrapper
welding power source.
Primary
to Circuit
of the
1ft~ ~I~
n-~
__
54
1
A
AAAA ____
__
r4::3-~>~
~3-11
>>~~~-<
___
~3-1
2
Ei
3
I
4~J
5
7
R:3-~>>
rl
SB-173 544-D
Figure
OM-157 066
Page
16
5-1. Circuit
Diagram For Welding
Power Source
SECTION 6- PARTS LIST
~T Hardware is common and
not available unless listed.
ST-800 930-C
Figure
NOTE: All items indented
Item
No.
1
2
Part
No.
by
a
dot(s)
are
6-1. Main
included with the item listed
Description
Item
No.
Part
No.
Assembly
directly
above.
I
Description
J
Item
No.
Part
No.
Description
146 168
Enclosure Panel
152 862
097 924
Knob
083 526
Housing Rcpt & Sockets
Baffle w/Cmpts
009 970
Rectifier Bracket
048 282
Receptacle w/Sockets
143810
RearPanel
128 755
Switch, DPST
153 197
Selector Switch
Clamp
148956
Switch Handle
Fig
6-2
Grommet
Support
3
171 658
Transformer
169654
Tank Bracket
4
602 250
Washer, flat
044 426
Cable
5
070 799
Wheel
8
602 387
Cylinder Chain
175060
Front Panel
6
171 213
Stabilizer
9
146165
Side Panel,LH
155 418
Front Control Panel
10
089899
Latch
171 639
Control Plate
174842
Nameplate
144 127
Cover, module opening
057357
Bushing, 1.l25mtg
Rear Panel
7
w/Cmpts
148 808
Fan Motor
11
146167
Side Panel
150 783
Fan Blade
12
134 464
049 399
Speed
Nut
13
+170 513
Warning Label
Wrapper
116996
GasValve
14
047 721
Cord Set
605 227
Nylon Nut,
15
146161
Base
146524
Hose
16
135390
Axle
149332
Hose
152 742
Rectifier
048 420
.750
Clamp
17
121 614
18
091 685
Capacitor
605741
Retaining Ring
Clip
183581
Gas Hose
600318
Weld Cable
130 750
Ground
173 374
Lock Washer
Diode, RP
19
602213
037 956
Diode, SP
Washer, .750
20
008 999
Caster
21
601 871
Jam Nut
Half Nut, .750-16
Thermostat, NC
22
171 600
026 947
Stand-Off
605 884
Handle
See Gun Owners
23
Manual
Resistor
037 957
605886
143974
Front Panel
Clamp
Regulator/Flowmeter
+When ordering
a
component originally
displaying a precautionary label, the label
w/Cmpts
should also be ordered.
160 775
Light
Be
035 897
Potentiometer
when
to provide Model and Serial Number
ordering replacement parts.
sure
OM-157 066
Page
17
2
~H~17
p3
Fig
19
6-3
20
-21
31
27
29
30
ST-800 931-8
Figure
NOTE: All items indented
Item
No.
Part
No.
by
a
dot(s)
are
174 861
Drive
2
148956
Switch Handle
3
021 469
Danger
4
144933
5
058 427
6
085980
Nut
7
605 941
8
057 543
9
w/Components (Fig
included with the item listed
Description
1
6-2. Baffle
Assembly, (Fig 6-3)
I
j
Item
No.
Part
No.
directly
6-1 Item
3)
above.
Description
]
Item
No.
Part
No.
083 431
Circuit Breaker
center
25
011 609
Toggle Switch,
LH & RH
26
171 610
Selector Switch
083147
Grommet
17
082 902
18
092 186
Access Door
19
156517
Strip, mtg
Strip, mtg
Capacitor
Retaining Ring
20
186355
Contactor
114786
Link
Flat Washer
21
134 201
PC Card Stand-Off
22
173002
Motor
057971
Spring, .845 OD
Keyed Washer
23
*012 658
10
010 191
Fiber Washer
11
058628
Brake Washer
23
*073 426
12
057 745
13
058 428
165 896
Connector & Sockets
*Recommended
14
177307
Spring, 2.430 OD
Hub, spool
Support Reel
135 558
Connector & Sockets
Be
15
174812
Baffle
165 745
Connector & Sockets
when
OM-157 066
Page
18
Label
Description
24
16
153 322
Terminal
038618
Link
28
010199
29
039 047
Speed Control Card
Fuse, mintr gI slo-blo
30
039 046
128 750
Tubing
Output Terminal,
Output Terminal,
Capacitor
2A 125V
31
071 971
Cover
Fuse, mintr gI slo-blo
5A 125V
27
SPDT
Assembly, pri
2V
red
black
OPTIONAL
Spare
Parts
Model and Serial Number
provide
ordering replacement parts.
sure
to
See Table 6-1
Drive Roll & Wire Guide Kits.
13
8.
10
7
6.
5
4
15
16
21
17
20
ST-148 529-C
18
Figure
Item
No.
Part
No.
I
j
Description
6-3. Wire Drive And Gears
Item
No.
Part
No.
(Fig
Description
6-2 Item
1)
Part
No.
Item
No.
1
602009
Screw, .250-20
12
151 828
Cotter Hair Pin
2
172075
Carrier, drive roll
13
173616
Cover, motor
3
166072
Spacer
14
173435
Motor
4
010224
15
079 633
Fitting,
5
182788
Spring Pin
Housing, adapter
16
601 966
6
085242
Fastener
17
145 237
Cover
7
085 244
18
604 538
Washer, flat
8
010231
Cupped
Spring
19
124778
Knob
OPTIONAL
9
085243
Knob
20
173 619
Carrier, drive roll
*Recommended
10
166071
Pressure Lever
21
174609
Be
11
079634
Hinge
Pin
22
174610
Screw,M4.7x12
Screw,M61.0x20
x
Washer
1.25
23
173620
Bushing
056 192
Wire Guide, .023/025 &
.030-035
193
056
hose 3/1 6tbg
Screw, .37516x 1.25
045 233
Stop
010287
Wire
Guide,
.045
Guide, anti-wear
Wrench,hex
Spare
Parts
provide Model and Serial
ordering replacement parts.
sure
when
Description
to
OM-157 066
Number
Page
19
Table 6-1. Drive Roll And Wire Guide Kits
IMPORTANT: Base selection of drive rolls upon the
1. V-Grooved rolls for hard wire.
following
2.
U- Grooved rolls for soft and soft shelled cored wires.
3.
U-Cogged
4.
V-Knurled rolls for hard shelled cored wires.
5.
Drive roll types may be mixed to suit
rolls for
extremely soft shelled
wires
recommended usages:
(usually hard surfacing types).
particular requirements (example:
V-Knurled roll in combination with
U-Grooved).
Wire Diameter
Drive Roll
.
Kit No.
Inlet
Wire Guide
Part No.
Type
087 131
087 130
V-Grooved
056 192
mm
079 594
053 695
V-Grooved
056 192
.035 in.
0.9mm
079 595
053 700
V-Grooved
056 192
.045 in.
1.2
079 596
053 697
V-Grooved
056 193
Fraction
Decimal
Metric
.023/.025 in.
.023/.025 in.
0.6mm
.030 in.
.030 in.
0.8
.035 in.
.045 in.
mm
Ref. S-0026-B/7-91
OM-1 57 066
Page
20

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