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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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