Miller GOLD SEAL MODEL 440 Owner's Manual

 (7) мне:
Gold Seal‘
June 1995
Form: OM-1312A
Effective With Serial No. KF919561
OWNERS
MANUAL
Gold Seal" Model 440
For GMAW And FCAW Weiding
Includes Gun And Gas Valve
CV/DC Welding Power Source/Wire Feeder
150 Amperes, 22 Volts At 40% Duty Cycle
Uses 230 Volts AC, Single-Phase Input Power —
Feeds .023 Thru .035 in {0.58 Thru 0.89 mm) Wire
Overheating And Overioad Protection
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
AA
E Give this manual to the operator.
@ For help, call your distributor
1079, Appleton, WI 54912
a or: MILLER ELECTRIC Mig.
Co., P.O. Box
414-734-9821
cover 5/94 — ST-800 B20-A
(© 1995 MILLER Electric Mig. Co.
PRINTED IN USA
<a
MILLER’S TRUE BLUE™ LIMITED WARRANTY
Effective January 1, 1995
(Equipment with a serial number preface of "KD” or newer)
This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY — Subject to the terms and conditions below, MILLER Electric
Mig. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold after the effective date of this limited warranty is free of de-
facts in material and workmanship at tha time it is shipped by MILLER. THIS WAR-
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-
NESS.
Within the warranty periods listed below, MILLER will repair or replace any war-
ranted pans or components that fail due to such defects in material or workmanship.
MILLER must be notified in writing within thirty (30) days of such defect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to be
followed.
MILLER shall honor warranty claims on warranted equipment listad below in the
event of such a failure 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 a North American distributor or eighteen
months after the equipment is sent to an International distributor.
1. 5 Years Parts - 3 Years Labor
* Orginal main power rectifiers
" Inverters {input and output rectifiers only)
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitigs
* Robots
3. 2 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
* Air Compressors
4. 1 Year — Parts and Labor
* Motor Driven Guns
* Process Controllers
* |HPS Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Spot Welders
* Load Banks
* SDX Transformers
* Running Gear/Trailers
* Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)
* Tecumseh Engines
* Deutz Engines (outside North America)
* Field Options
(NOTE: Field options are covered under True Blue 'M for the remaining
warranty period of the product they are installed in, or for a minimum of
one year — whichever is greater.)
5. 6 Months — Batteries
6. 90 Days — Parts and Labor
* MIG Guns/TIG Torches
* AFT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
" Remote Controls
, Accessory Kits
” Replacement Parts
MILLER'S True Blue ' Limited Warranty shall not apply to:
1. Items fumished by MILLER, but manufactured by others, such as engines or
trade accessories. These items are coverad by the manufacturers warranty, if
any.
2. Consumable components; such as contact tips, cutting nozzles, contactors
and relays or parts that fail due to normal wear.
3. Equipment that has bean modified by any party other than MILLER, or equip-
ment that has been improperly installed, improperly operated or misused
based upon industry standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has been used for operation
outside of the specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE 8Y COMMER-
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT,
in the event of a warranty claim covered by this warranty, the exclusive remedies
shall be, at MILLER'S option: (1) repair; or (2) replacement; or, where authorized in
writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace-
ment at an authorized MILLER service station; or (4) payment of or credit for the pur-
chase price (less reasonable depreciation based upon actual use) upon retumofthe
goods at customer's risk and expense. MILLER'S option of repair or replacement
wilt be F.O.B., Factory at Appleton, Wisconsin, orF.O.B. ata MILLER authorized ser-
vice facility as determined by MILLER. Therefore no compensation or reimburse-
ment for transportation costs of any kind will be allowed.
TO THE EXTENT PEAMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON-
TRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR-
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN-
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER 1S EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty
iasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides spe-
cific legal rights, and other rights may be available, but may vary from stata to state.
In Canada, legislation in some provinces provides for certain additional warranties
or remedies other than as stated herein, and to the extent that they may not be
waived, the limitations and exclusions set out above may not apply. This Limited
vary from province to province.
ZN vary ton provides specific legal rights, and other rights may be available, but may
RECEIVING-HANDLING
Model
When requesting information about this equipment, always provide Model Designation and Serial or Style Number.
Serial or Style No.
Date of Purchase
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for {oss or damage
with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturer's
Transportation Department.
Use the following spaces to record Mode! Designation and Serial or Style Number of your unit. The information is located on the rating label
or nameplate.
miller 6/95
SECTION 1 —- SAFETY INFORMATION
mod1.1 2/93
B Read all safety messages throughout this manual.
@ Obey ail safety messages to avoid injury.
E Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol
2 Signal Word
1 2 2
WARNING means possible death
or serious injury can happen.
3 CAUTION means possible minor
ELECTRIC SHOCK can kill.” injury or equipment damage can
® Do not touch live electrical parts. | ® Keep away from moving parts. happen.
® Disconnect input power before 4 C2 ® Keep all panels and covers closed 3 Statement Of Hazard And
installing or servicing. | when operating. Result
/ 4 Safety instructions To Avoid
5 Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
READ SAFETY BLOCKS at start of
6 LAS | Section 3-1 before proceeding. Read safety blocks for each sym-
ni, bol shown.
7 NOTE
77 NOTE (7 Turn Off switch when using high frequency. Special instructions for best oper-
ation — not related to safety.
Figure 1-1. Safety Information
Table 2-1. Welding Power Source
Specifications Description
Type Of Output Direct Current/Constant Voltage (CV/DC)
Rated Weld Output 150 Amperes, 22 Volts DC At 40% Duty Cycle (See Section 2-2)
Type Of Input
Input Amperes At Rated Output
input Amperes Used While Idling
KVA/KW Used At Rated Output
KVA/KW Used While Idling
Max. Open-Circuit Voltage
Control Circuit Voltage At Gun
Welding Processes
Calculated Wire Feed Speed At No Load
Approximate Wire Feed Speed Range
Wire Diameter Range
Input Power Cord With Plug
Overall Dimensions
Weight
Single-Phase; 230 Volts AC; 60 Hertz
26 Amperes
1.4 Amperes
5.9 kVA/4.9 kW
.33 kVA/.16 kW
32 Volts DC
24 Volts AC
Gas Metal Arc Welding (GMAW) (Uses Solid Hard Or Aluminum Wire And External
Shielding Gas)
Flux Cored Arc Welding (FCAW) (Uses Wire With Flux Inside And Requires No External
Shielding Gas)
0 To 840 ipm (0 To 21.3 mpm)
0 To 740 ipm (0 To 18.8 mpm)
.023 To .035 in (0.58 To 0.83 mm)
5 ft (1.5 m)
Length: 34 1/2 in (876 mm); Width: 18 1/2 in (470 mm), Height: 32 in (813 mm)
Net: 158 Ib (72 kg); Ship: 178 16 (81 Ка)
OM-1312 Page 1
Table 2-2. Welding Gun
Specifications
Description
Ampere Rating
Duty Cycle
Wire Size Range
Cable Length
Cooling Method
160 Amperes
10 ft (3 m)
Air
60% Using CO» Shielding Gas Or Self-Shielding (Flux Cored) Wire (See Section 2-2)
‚023 To .035 in (0.58 To 0.89 mm)
2-1. Volt-Ampere Curves
The volt-ampere curves show the
40 | minimum and maximum voltage
RANGES and amperage output capabilities of
the welding power source. Curves
30 — of other settings fall between the
> OS curves shown.
10
о
0 50 100 150 200 250
DC AMPERES
ssb1.1 10/91 / ST-173 177
Figure 2-1. Volt-Ampere Curves
2-2. Duty Cycle
4 CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage unit or gun and void warranty.
wiwams.2 8/93
® Do not weld at rated load longer than shown below.
0 Definition
EN
10 Duty Cycle is percentage of 10
minutes that unit or gun can
weld at rated load without over-
Minutes heating.
Chart
600
500
en 400
Ш
- - —
= 200 Ps
Pr
=
150
>
100 —
10 15 20 25 30 40 50 60 70 80 90100
% DUTY CYCLE
v UNIT 40% Duty Cycle At 150 Amperes
4 Minutes Welding 6 Minutes Resting
7 GUN 60% Duty Cycle At 160 Amperes Using CO,
— N
6 Minutes Welding 4 Minutes Resting
GUN 30% Duty Cycle At 160 Amperes Using
Mixed Gases
N
3 Minutes Welding 7 Minutes Resting
sb1.3 8/93 - ST-173 553
OM-1312 Page 2
Figure 2-2. Welding Power Source Duty Cycle Chart
SECTION 3 — INSTALLATION
Table 3-1. Items Included With Welding Power Source
item Quantity
Welding Gun — Shipped Set To Feed .030 in (0.8 mm) Wire 1
10 ft (3m) Work Cable And Clamp 1
Contact Tips (3 — .023 in, 2 — .030 in, And 3 —.035 in) 8
NOTE (7 Customer must obtain proper welding wire and shielding gas for desired
application.
3-1. Installing Work Clamp
Insulator
Boit
Smalier Hole
Work Clamp Tabs
Bend tabs around work cable.
5 Work Cable From Unit
6 Nut
> © № —
Tools Needed:
J"
3/8, 7/16 in
Raf. ST-025 190-C
Figure 3-1. Work Clamp Installation
3-2. Installing The Running Gear
tnstall running gear, handle, and
cylinder bracket as shown (see
Parts List for parts descriptions).
Crimp S-hook and
snap to chain.
Install cylinder bracket here when
using a small gas cylinder.
Tools Needed:
>
Remove paint from axle grooves
before installing retaining rings. EH 3/8in
ST-800 821-B
Figure 3-2. Installing The Running Gear
OM-1312 Page 3
3-3. Installing Gas Supply
1 ve
CYLINDERS can explode if damaged.
e Keep cylinders away from welding and other |¥
electrical circuits.
® Never touch cylinder with welding electrode.
e Always secure cylinder to running gear, wall, or
other stationary support. wam4.1 9/91
BUILDUP OF SHIELDING GAS can harm
health or Kill.
e Shut off shielding gas supply when not-in use.
Obtain gas cylinder and chain to
running gear, wall, or other station-
ary support so cylinder cannot fall
and break off valve.
1 Cap
2 Cylinder Valve
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Ciose valve.
3 Cylinder
4 Requlator/Flowmeter
Install so face is vertical.
5 Gas Hose Connection
Fitting has 5/8-18 right-hand
3 threads. Obtain and install gas
hose between regulator/flowmeter
and fitting on rear panel of welding
power source.
; 6 Flow Adjust
Typical flow rate is 20 cíh (cubic
Argon Gas feet per hour). Check wire man-
ufacturer's recommended flow
rate.
5 Make sure flow adjust is closed
when opening cylinder to avoid
damage to the flowmeter.
7 CO» Adapter
-— 8 O-Ring
3 Install adapter with O-ring between
regulator/flowmeter and CO»
7 8 cylinder.
CO» Gas
Tools Needed:
Z—— 1-1/8, 5/8 in
ssb3.1* 5/94 — 57-159 697-A
Figure 3-3. Typical Regulator/Flowmeter Installation
3-4. Connecting To Weld Output Receptacles
A WARNING
== ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical equipment.
e Do not touch live electrical parts.
® Turn Off welding power source before making any weld output connections.
® Do not change position of welding cable connectors while welding.
® Be sure connectors are secure in receptacles before welding. swarm 12.2 2/03
OM-1312 Page 4
1 Positive (+) Weld Output Re-
ceptacle
2 Negative (~) Weld Output Re-
ceptacle
3 Weld Cable
4 Work Cable
For GMAW direct current electrode
positive {DCEP), connect weld
cable plug to positive (+) weld
output receptacle and work cable
plug to negative (-) weld output
receptacie.
For GMAW direct current electrode
negative (DCEN), reverse cable
connections.
For FCAW direct current electrode
4 negative {DCEN), connect weld
cable plug to negative (-) weld
output receptacle and work cable
plug to positive (+) weld output
receptacle.
For FCAW direct current electrode
positive (DCEP), reverse cable
connections. ST-800 B24
Figure 3-4. Weld Output Connections
3-5. Installing Welding Gun
1 Gun Securing Nut
2 Drive Assembly
3 Gun End
Loosen securing nut. Insert gun
end through front panel opening
until it bottoms against drive as-
sembly. Tighten nut.
4 Gun Trigger Plug
insert plug into front panel recep-
tacle, and tighten threaded collar.
Close door.
ST-800 822
Figure 3-5. Gun And Trigger Leads Connections
OM-1312 Page 5
3-6. Selecting A Location And Connecting Input Power
A WARNING
—
ELECTRIC SHOCK can Kill.
Do not touch live electrical parts.
Turn Off welding power source, and disconnect
input power before inspecting or installing.
Have only qualified persons install unit.
Installation mustmeet National Electrica! Code and
all other codes.
BLOCKED AIRFLOW causes
overheating and possible damage to
unit.
e Do not block or filter airflow
Warranty is void if any type of filter is used.
swarn3.1" 2/03
PRL ро,
LA
Have only qualified persons make
this installation.
1 18in (457 mm) Open Space
At Front And Rear
2 Rating Label
Supply correct input power.
3 Line Disconnect Device Of
Proper Rating
4 230 Volts AC Wall Receptacle
5 Input Conductors
6 Grounding Conductor
Select size and length using
Table 3-2. Conductor rating must
comply with national, state, and
local codes.
Install and connect grounding con-
ductor and input conductors in
conduit or equivalent between wall
receptacle and deenergized line
disconnect device.
Connect grounding conductor first,
then line input conductors.
7 Overcurrent Protection
Select type and size using
Table 3-2. Install into deenergized
line disconnect device (fused dis-
connect switch shown).
8 Input Power Plug
Turn Off unit Power switch, and
connect plug to wall receptacle.
Place line disconnect switch in On
position before using welding
power source.
ssb2.2* 11/93 — ST-B00 823-À
Figure 3-6. Location And Input Power Connections
Table 3-2. Electrical Service Requirements*
Input Voltage 230
Input Amperes At Rated Output 26
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 40
Min input Conductor Size In AWG/Kcmil 12
Max Recommended Input Conductor Length In Feet (Meters) 80 (24)
Min Grounding Conductor Size In AWG/Kcmil 12
Reterence: 1993 National Electrical Code (NEC). S-00924
OM-1312 Page 6
3-7. Installing Wire Spool
A WARNING
— ELECTRIC SHOCK can Kill.
e Donottouch live electrical parts.
® Turn Off welding power source, and disconnect input power before inspecting or installing.
swam1.1 293
NOTE 7 If hub tension is too tight, circuit breaker CB1 can open (see Section 5-2). If hub
tension is too loose, wire unravels and can become tangled inside unit.
FOR STANDARD WIRE SPOOL: Turn Off and unplug unit.
1 Wire Spool
2 Gun Contact Tip
If necessary, cut welding wire off at
contact tip, and retract wire onto
spool and secure.
3 Retaining Pin
Remove pin and pull off spool.
4 Hub
5 Hub Pin
6 Bushings
Install bushings when using a 1 Ib
spool.
Slide spool onto hub so wire feeds
oft bottom. Tum spool until hub pin
fits hole in back of spool. Push
retaining pin through hub.
7 Hub Tension Nut
Grasp spool in one hand and turn
while using a wrench to adjust hub
tension nut. When a slight force is
needed to turn spool, tension is
set.
FOR 1 LB WIRE SPOOL:
5
Close and secure pressure roll
assembly. Thread welding wire
(see Section 3-8). Close door.
Remove and retain — install 1 Ib spool
Tools Needed:
==>
=
>
Ref. ST-B00 826 / 5-0499 / ST-BOO 316
Figure 3-7. Installing Wire And Adjusting Tension
OM-1312 Page 7
3-8. Threading Welding Wire
A WARNING
WELDING WIRE can cause puncture
wounds.
e Donot press gun trigger until instructed to do so.
® Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
CYLINDERS can explode if damaged.
e Keep cylinders away from welding and other
electrical circuits.
® Never touch cylinder with welding electrode.
e Always secure cylinder to running gear, wall, or
other stationary support.
HOT SURFACES can burn skin.
e Allow gun to cool before touching.
T4 ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger. |
swarn2.1 9/91 / swarn5.1 10/91
OM-1312 Page 8
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Outlet Wire Guide -
Gun Conduit Cable
Lay gun cable out straight.
dl ©) ло о (2 NN +
Tools Needed:
HH eT
Hold wire tightly to keep
it from unraveling.
6 in — A:
(150 mm) (105 mm)
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.
Tighten
Close and tighten pressure assembly, Remove gun nozzle Set switch.
and let go of wire. and contact tip.
Welding wire is electrically
live when feeding welding
wire with gun trigger. р
Press gun trigger until wire Feed wire to check drive roll pressure. Cut off wire.
comes out of gun. Reinstall Tighten knob enough to prevent slipping. Close and latch door.
contact tip and nozzie.
Ref. ST-800 826 / Ref. ST-171 158-A / S-0627-A
Figure 3-8. Threading Welding Wire
OM-1312 Page 9
SECTION 4 — OPERATION
1 ¿q
ELECTRIC SHOCK can kill.
e Always wear dry insulating gloves.
e Insulate yourself from work and ground,
® Do not touch live electrical parts.
e Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
® Wear welding helmet with correct shade of filter.
e Wear correct eye, ear, and body protection.
FUMES AND GASES can be hazardous
to your health.
® Keep your head out of the fumes.
e Ventilate area, or use breathing device.
e Read Material Safety Data Sheets (MSDSs) and
manufacturer's instructions for material used.
WELDING can cause fire or explosion.
® Do not weld near flammable material.
® Watch for fire; keep extinguisher nearby.
® Do not locate unit over combustible surfaces.
® Do not weld on closed containers.
e Allow work and equipment to cool before handling.
MOVING PARTS can cause injury.
e Keep away from pinch points such as drive rolls.
® Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
® Pacemaker wearers keep away.
e Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
See Safety Precautions at beginning of manual for ba-
sic welding safety information. swam6.2* 10/91
Wear the following while welding:
1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
Figure 4-1. Safety Equipment
Tools Needed:
tint
1 Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
as close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4,1 2/93
Figure 4-2. Work Clamp
BUILDUP OF SHIELDING GAS can harm health or Kill.
e Shut off shielding gas supply when not in use.
wam1.1 9/91
1 Shielding Gas Cylinder
2 Valve
3 Gun Trigger
Open valve on cylinder just before
welding.
Gun trigger turns weld output and
gas flow on and ofi.
Close vaive on cylinder when fin-
ished welding. «hs | 6/92 — S-0621-C
Figure 4-3. Shielding Gas
OM-1312 Page 10
4 CAUTION
ARCING can damage switch.
® Do not change Voltage switch position while welding.
Arcing inside switch can damage contacts, causing switch to fail. warn5.1* 2/03
1 Wire Speed Control
Use control to select a wire feed
speed. As Voltage switch setting
increases, wire speed range also
increases. The numbers around
the control are not a wire feed
speed and are for reference only.
2 Voltage Switch
Use switch to select an arc voltage.
The higher the selected number,
the thicker the material that can be
welded.
3 Power Switch
4 Pilot Light
Use switch to turn unit, fan, and
pilot light On and Off.
THICKNESS
3
Y
76
5
Raf. ST-800 824 / Ref. ST-170 725-A / Ref. ST-171 158-A / Ref. ST-171 158
Figure 4-4. Controls
OM-1312 Page 11
Install & Put On Turn On Do Readjust Controls
Connect Personal Safety Equipment & Gas Set Controls Sample Weld And Prepare
Equipment Ur Applicable) For Welding
Equipment
ssb4.1* 10/91
Figure 4-5. Sequence Of Operation For Hard And Flux Cored Wires
Install & Connect Adjust Hub Adjust Drive Rol Put On Personal yun On Equipmen oo Controls &
Equipment Usin ension To ressure To n ust Gas eep Gun Cable
hun J Minimum Safety Equipment To 80 cfh Straight
Knurled Groove Minimum
Readjust Controls
Do Sample Weld And Prepare For
Welding
Figure 4-6. Sequence Of Operation For Aluminum Welding
SECTION 5 — MAINTENANCE & TROUBLESHOOTING
4 WARNING
— ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
MOVING PARTS can cause injury.
® Keep away from moving parts.
® Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
HOT PARTS can cause severe burns.
® Allow cooling period before maintaining or
servicing.
e Keep away from pinch points such as drive rolls.
Maintenance to be performed only by qualified
persons. swamB.2 2/93
5-1. Routine Maintenance
@ TymOft all power before maintaining.
I 3 Months I 3 Months I 6 Months
= re
DEY me) | Po == fo
eplace eplace Е Or
See Unreadabie + Cracked de OR e Vacuum
Section Labels Parts AI Inside
8 a Trigger Cord
During Heavy Service,
Tape Or -- Clean Monthly
Replace
Cracked
=> Weld Clean
-- Cable Gas Hose Gun Cable Drive
Rois
5-3
Figure 5-1. Maintenance Schedule
OM-1312 Page 12
5-2. Overload Protection
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Turn Off and unplug unit. Unlatch
door, and remove door/wrapper.
1 Fuse F2
2 Fuse F1
Puli fuse(s) from fuse holder, and
check and replace if needed. To
reinstall, push fuse into fuse
holder.
Reinstali wrapper, and latch door.
Tools Needed:
(0 3/8in
Gus
Ref. ST-800 825-A
Figure 5-2. Fuse F1 Location
1 Circuit Breaker CB1
C81 protects the wire feeder motor
from overdoad. If CB1 trips, wire
feeding stops. Check for jammed
wire or misaligned drive roil. Cor-
rect problem.
Close door.
Ref. ST-800 826
C. Overheating
Minutes
When overheated, thermostat Let fan run for Start welding.
opens, output stops, and cooling 15 minutes.
fan keeps running.
58b10.1 1/94 — ST-800 820-A
Figure 5-4. Overheating
OM-1312 Page 13
5-3. Cleaning Or Repairing Drive Assembly
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Turn Off and unplug unit.
1 Wire Spool
2 Gun Contact Tip
Cut weiding wire off at contact tip.
Retract wire onto spool and se-
cure.
3 Pressure Roll Arm
4 Cotter Pin
5 Pin
6 Screw
7 Beanng
Remove bearing as shown. Install
new bearing and secure with
screw. Reinstall arm onto pin and
secure with cotter pin.
8 Setscrew
9 Smooth Groove For Hard
Wire
10 Drive Roll
Remove drive roll as shown.
Use a wire brush to clean drive roll.
Push drive roll onto shaft with
desired groove in. Tum drive roll so
one setscrew faces flat side of
shaft, and tighten both setscrews.
11 Knurled Groove For Flux
Cored Wire
12 Wire Inlet Guide
Remove guide by pressing on
barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole
from rear until it snaps in place.
Thread welding wire (see Section
3-8). Close door.
Ref. ST-800 826 / ST-155 578
Figure 5-5. Removing Drive Roll, Drive Bearing, And Wire inlet Guide
5-4. Replacing Gun Contact Tip
A WARNING
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Tools Needed:
=P
=
Turn Off and unplug unit.
1 Nozzle
2 Contact Tip
Cut off welding wire at contact tip.
Remove nozzie.
Remove contact tip and install new
contact tip. Reinstall nozzie.
Rai. ST-149 632-C
Figure 5-6. Replacing Contact Tip
OM-1312 Page 14
5-5. Cleaning Or Replacing Gun Liner
+ READ SAFETY BLOCKS at start of
41 WARNING AY 4 Section 5 before proceeding.
Á
FLYING METAL CHIPS AND DIRT can cause injury and damage equipment.
® Point gun away from people and in a safe direction when blowing out with compressed air.
swarni0.1 10/81
AA Turn off welding power 7
source/wire feeder. Tools Needed:
N
` ~~» E
N
\ dE 3/8in
Head Tube
3/8 in
Remove nozzle,
contact tip, and
liner collet.
Ne
e
A
Remove liner.
Cone E To Reassemble Gun:
«” Blow out — Install contact tip.
gun casing. Insert new liner.
Install collet onto liner and tighten
into gunfeeder connector using
wrench.
Cut liner off near collet so that liner
endis as close to drive rolls as pos-
sible without touching.
Install nozzle.
Ref. ST-155 509
Figure 5-7. Replacing Gun Liner
OM-1312 Page 15
5-6. Troubleshooting
A WARNING
— ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
® Turn Off welding power source, and disconnect
input power before inspecting, maintaining, or
servicing.
MOVING PARTS can cause injury.
® Keep away from moving parts.
e Keep away from pinch points such as drive rolls.
HOT PARTS can cause severe burns.
e Allow cooling period before servicing gun or unit.
A
fn
Troubleshooting to be performed only by qualified
posa
persons. swam9.2 2/93
Table 5-1. Welding Trouble
Trouble Remedy Section
No weld output; wire does not feed; fan |— — | Secure power cord plug in receptacle. ——. 3-6
does not run.
Replace line disconnect fuse or reset circuit breaker if open. — — >> 3-6
Secure gun trigger plug in receptacle or repair leads, or replace |— — + 3-5
trigger switch.
No weld output; wire does not feed; fan ¡— — -e| Thermostat TP1 open (overheating). Allow fan to run; the thermo- |— — — 5-26
motor continues to run. stat will close when the unit has cooled.
Check circuit breaker CB1, and reset if necessary. — — 5-2B
| No weld output; wire feeds. — — -—| Connect work clamp to get good metal to metal contact. — — = Figure 4-2
Check for proper weld cable connections. —— 3-4
Replace contact tip. — — = 5-4
Low weid output. |-- — - Connect unit to proper input voltage or check for low line voltage. — — | 36 |
Table 5-2. Wire Drive/Gun Trouble
Trouble Remedy Section
Electrode wire feeding stops during |—— -=| Straighten gun cable and/or replace damaged parts. ——. 5-5
welding.
Adjust drive roll pressure. —— 3-8
Change to proper groove. ——. 5-3
Readiust hub tension. ——. 3-7
Replace contact tip if blocked. — — 5-4
Clean or replace wire inlet guide or liner if dirty or plugged. ———+#| 5-3, 5-5
Replace drive roll or pressure bearing if worn or slipping. — — 5-3
Secure gun trigger plug in receptacle or repair leads, or replace |— — > 3-5
trigger switch.
Check circuit breaker CB1, and reset if necessary. ——- 5-2B
Check and clear any restrictions at drive assembly and liner. — — 5-5
Have nearest Factory Authorized Service Station/Service Distrib- |— — — --
utor check drive motor.
OM-1312 Page 16
SECTION 6 — ELECTRICAL DIAGRAMS
TT SS SS SM] ]”; O] M];rTrcs TM M—o—;——————ú_—].————É]——;Ú—L.U———]——]]z ">
PLG2C SIA
{
230VAC <
<TH
518
SB-170 520
Figure 6-1. Circuit Diagram For Welding Power Source
OM-1312 Page 17
SECTION 7 — WELDING METHODS & TROUBLESHOOTING
maod4.1 4/52
A WARNING
ELECTRIC SHOCK can kill.
e Always wear dry insulating gloves.
e Insulate yourself from work and ground.
| ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
e Wear welding helmet with correct shade of filter.
e Wear correct eye, ear, and body protection.
e Do not touch live electrical parts.
e Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous
MOVING PARTS can cause injury.
e Keep away from pinch points such as drive rolls.
e Keep all doors, panels, covers, and guards closed
and securely in place.
to your health.
e Keep your head out of the fumes.
e Ventilate area, or use breathing device.
® Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
® Pacemaker wearers keep away.
e Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
WELDING can cause fire or explosion.
® Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
WELDING CURRENT can damage elec-
tronic parts in vehicles.
e Disconnect both battery cables before weldingon a
vehicle.
® Place work clamp as close to the weld as possible.
.
.
e Do not weld on closed containers.
e
Allow work and equipment to cool before handling.
See Safety Precautions at beginning of manual for ba-
sic welding safety information. swam6.2 10/91
7-1.
Flux Cored Arc Welding (FCAW) And Gas Metal Arc Welding (GMAW)
NOTE C7
Welding wire is not energized until gun trigger is pressed; therefore, welding wire
should extend not more than 1/2 in (13 mm) beyond edge of nozzle and tip of wire
placed on seam betore lowering helmet and pressing trigger.
1 Hold Gun And Control Gun
Trigger
2 Workpiece
3 Work Clamp
Electrode Extension
3 (Stickout) 1/4 To 1/2 in (6 To
13 mm)
Cradle Gun And Rest Hand
On Workpiece
5
В
AT
4
|
|
907 90°
End View Of Work Angle Side View Of Gun Angie End View Of Work Angle Side View Of Gun Angle
GROOVE WELDS FILLET WELDS 5-0421-A
OM-1312 Page 18
Figure 7-1. Holding And Positioning Welding Gun
NOTE (7 Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.
D 10° | a! 10°
pas нана
Push Perpendicular Drag
GUN ANGLES AND WELD BEAD PROFILES
Short Normal | Long
ELECTRODE EXTENSIONS {STICKOUT)
Short Normal Long
FILLET WELD ELECTRODE EXTENSIONS {STICKOUT)
A “a
¿ 5
Slow Normal Fast
GUN TRAVEL SPEED S-0634
Figure 7-2. Conditions That Affect Weld Bead Shape
N OT E (7 Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads works better.
1 Stringer Bead — Steady
Movement Along Seam
2 Weave Bead - Side To Side
Movement Along Seam
3 Weave Patterns
Use weave patterns {0 cover a
wide area in one pass of the elec-
trode. Do not let weave width ex-
ceed 2-1/2 times diameter of
electrode.
3
ARA DN
5-0054-A
Figure 7-3. Gun Movement During Welding
OM-1312 Page 19
Large Spatter Deposits
Rough, uneven bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
POOR WELD BEAD
a >» WN =—
5-0053-A
1 Fine Spatter
GOOD WELD BEAD 2 Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in (3.2 mm) thickness in metals
being welded.
4 No Overlap
5 (Good Penetration Into Base
Metal
5-0052-B
Figure 7-4. Weld Bead Characteristics
7-2. Welding Troubleshooting
Table 7-1. Porosity
Porosity — small cavities or holes
resulting from gas pockets in weld
metal.
50635
Possible Causes
Corrective Actions
Inadequate shielding gas coverage.
Check for proper gas flow rate.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Eliminate drafts near welding arc.
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas. Use welding grade shielding gas; change to different gas.
Dirty welding wire. Use clean, dry welding wire.
Eliminate pick up of oil or {ubricant on welding wire from feeder or liner.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of
nozzle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
OM-1312 Page 20
Table 7-2. Excessive Spatter
Excessive Spatter — scattering of
molten metal particles that cool to
solid form near weld bead.
S-0636
Possible Causes
Corrective Actions
Wire feed speed too high.
Select lower wire feed speed.
Voltage too high.
Select lower voltage range.
Electrode extension (stickout) too long.
Use shorter electrode extension (stickout).
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.
Increase fiow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
Table 7-3. Incomplete Fusion
Incomplete Fusion — failure of weld
metal to fuse completely with base
metal or a preceeding weld bead.
5-0637
Possibie Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input.
Select higher voltage range and/or adjust wire feed speed.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during weiding.
Momentarity hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
Table 7-4. Lack Of Penetration
Lack Of Penetration — shallow fu-
sion between weld metal and base
metal.
Lack of Penetration
Good Penetration S-0638
Possible Causes
improper joint preparation.
Corrective Actions
Material too thick. Joint preparation and design must provide access to bottom of groove while maintain-
ing proper welding wire extension and arc characteristics.
Improper weld technique.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddie.
Be sure welding wire extends not more than 1/2 in {13 mm) beyond nozzle.
Insufficient heat input.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
OM-1312 Page 21
Table 7-5. Excessive Penetration
Excessive Penetration
Excessive Penetration - weld metal
melting through base metal and hanging
underneath weld.
Good Penetration 5-0639
Possible Causes
Corrective Actions
Excessive heat input.
Select lower voHage range and reduce wire feed speed.
Increase travel speed.
Table 7-6. Burn-Through
Burn-Through —weld metal melting
completely through base metal
resulting in holes where no metal
remains.
5-0640
Possible Causes
Corrective Actions
Excessive heat input.
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
Table 7-7. Waviness Of Bead
Waviness Of Bead ~ weld metal
that is not parallel and does not
cover joint formed by base metal.
S-0641
Possible Causes
Corrective Actions
Welding wire extends too far out of
nozzle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Unsteady hand.
Support hand on solid surface or use two hands.
Table 7-8. Distortion
Distortion — contraction of weld
metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead. 5.0642
Possible Causes
— —
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-1312 Page 22
NOTES
OM-1312 Page 23
SECTION 8 — PARTS LIST
ST-801 117
Figure 8-1. Main Assembly
OM-1312 Page 24
Parts For Main Assembly
NOTE: All items indented by a dot(s) are included with the item listed directly above.
item Part item Part Нет Part
No. No. Description No. No. Description No. No. Description
1 170769 Side Panel 30 Rear Panel w/cmpts 38 070799 Wheel
2 +170767 Wrapper 170773 - Rear Panel 39 602250 Washer, flat
134 464 Warming Label 148 808 - Fan Motor 40 121614 Retaining Ring
089899 Latch 150 783 - Fan Blade 41 1170760 Mounting Capacitor Bank
3 174654 Handle 605855 - Contactor 42 170759 Mounting Capacitor
108942 Screw, 1/4-20 x 1-1/4 034 260 - Connecting Link 43 170921 Capacitor
604 583 Screw, No. 12 x 1/2 170970 - Valve 44 175163 Resistor
126 838 Drive Assembly 098 376 - Fuse Holder 45 008 999 Caster
4002237 Ko 05078 Foe А 49170756 Fun our
. * Fuse asher, fla
° jo a. | oe 4 Wache 000174 - Relay 48 602213 Washer, lock
7 085242 Fastener 082 722 —- Varistor 49 601871 Nut, 3/8-16
035 704 - Rectifier, integrated 50 Front Panel wempis
8 010224 Spring Pin 170904 - Rectifier, si diode 174 653 - Front Panel
9 058549 - Wire Guide 168349 - Diode, SP 153197 . Selector Switch
10 124817 - Drive Housing 006334 - - Thermostat, NC 173055 - Lead Clamp
11 080416 - Hinge Pin 152862 - - Grommet 174717 - Switch Handle
12 151828 - Cotter Hair Pin 026947 … - Stand-Off 128 755 - Toggle Switch, DPST
13 112031 - Pressure Lever 048420 - - Capacitor 160775 - Light
14 090443 - Bearing 168 348 -- Diode, RP 087 640 - Twist Lock Receptacle
111 622 -- Spacer 047838 - Snap-In Blank, 1 in 170725 Nameplate
15 149332 Hose Clamp 070 371 -Snap-In Blank, 171158 Lower Nameplate
16 147635 Hose, (order by ft) 1-3/32/1-1/8 174788 - Polarity Cable
17 119028 Drive Roll 044 426 - Cable, clamp .690/1.0 097 924 - Knob
18 602169 Set Screw 174869 Hose, (order by fl) 153198 - Rheostat
19 129893 Insulator 149332 - Hose Clamp | 088 300 - Strain Relief
20 124508 Drive Motor 153501 - Connector & Pins 081560 - Receptacle, 4skt
21 010909 Nut 147 996 .. Connector Pins 174451 Work Cable
166 659 - Connector & Sockets 010368 Work Clamp
22 010910 Washer 147995 .. Connector Sockets 026 843 Vinyl Insulat
23 073355 Spring ny! Insulator
Ds: 31 057478 Tank Support 173374 Regulator/Flowmeter
24 111998 Cotter Hair Pin 602 154 Screw, 1/4-20 x 1/2
25 111929 Hub 32 602389 5-Hook +When ordering a component originally dis-
135615 Bushing, 3/4 OD x 3/4 lg 33 156340 Chain playing a precautionary label, the label should
26 170771 Baffle 34 602384 Snap - also be ordered.
27 083431 Circuit Breaker 35 047721 Cord Set “Recommended Spare Parts.
28 083912 Stabilizer 36 170762 Base Be sure to provide Model and Serial Number
29 170752 Transformer 37 135390 Axle when ordering replacement parts.
OM-1312 Page 25
item Part gs
No. No. Description
1 110793 Handle Assembly
110795 Head Tube
2 110780 -Nut
3 110779 - Jacket
4 110781 -Stop
5 128878 - Adapter
6 110782 - Spring
7 110785 Contact Tube, .023
7 110786 Contact Tube, .030
7 110787 Contact Tube, .035
8 110789 Nozzle, 1/2 orf
8 #112420 Nozzle, 3/8 orf
8 110790 Nozzle, flat spot
9 110794 Trigger Switch Assembly
14 10 080565 Terminal
e 11 110792 Cable
12 110797 Sleeve
13 167440 Liner, .023-.035
F< 14 110784 - Collet, .023-.035
15 15 079974 O-Ring, .500
16 16 110796 Connector
2 17 079878 Housing Plug & Pins
079535 - Terminal
18 048834 Clamp
17 ¢ OPTIONAL
18 Be sure to provide Model and Serial Number
when ordering replacement parts.
ST-110 832-D
Figure 8-2. GA-16C Gun
Table 8-3.Suggested Welding Settings (GMAW and FCAW)
ae Wi Material Thickness
and | eter Control 22 ga. | 18 ga. | 16 ga. | 14 ga. | 12 ga.
Settings to to to to to 10 ga. Above 10 ga.
Flow | (inch)
Rate 18 ga. | 16 ga. | 14 ga. | 12 ga. | 10 ga.
023 Thickness 2 2 2 3 4 4 — —
ЕО Wire Speed* | 30 45 50 60 70 80 — —
Mild | 989 Thickness 1 2 2 3 3 4 5 —
Sree Wire Speed* 10 15 20 20 30 50 50 -
20 cíh vas | Thickness 1 2 3 3 4 4 5 6
Wire Speed" | 15 15 20 25 30 40 40 45
ER70 023 Thickness 1 2 2 3 3 4 — on
e Wire Speed” 65 60 70 90 95 100 — —
Steel Thickness 1 1 2 3 3 4 5 6
75% .030
Argon Wire Speed" | 30 40 45 50 50 60 70 75
25% Thickness 1 1 2 3 3 4 5 6
CO» 035
20 cfh Wire Speed” 25 30 35 45 50 50 70 85
* Adjust Wire Speed Adjustment control as required. cfh = cubic feet per hour
IMPORTANT: /fin doubt, set Thickness switch for range desired and set Wire Speed Adjustment to 50. The weld can
be started and fine tuned during operation. If input voltage is low, a higher Thickness setting may be required to obtain
desired weld.
53-174 732-А
OM-1312 Page 26