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Common questions
Common Questions
10 total 1
What is the duty cycle rating of the Spoolmatic 30A?
The Spoolmatic 30A is rated at 100% duty cycle, allowing continuous operation when using argon shielding gas. Duty cycle is defined as how long the gun/feeder can operate within a ten minute period without causing overheating or damage. (Page 9)
2
What wire diameter range is compatible with the Spoolmatic 30A?
The Spoolmatic 30A accepts .025 through 1/16 in. (0.6 through 1.6 mm) aluminum wire, and .025 through .045 in. (0.6 through 1.1 mm) hard or cored wire. The maximum spool size is 4 in. (102 mm) in diameter. (Page 9)
3
What is the correct coolant mixture to use in the water-cooled Spoolmatic 30W model?
You must use only a mix of 50% distilled water and 50% high quality automotive antifreeze that does not contain stop-leak additives. Using incorrect coolant or coolant containing stop-leak additives can corrode and/or plug gun/feeder cooling passages, and use of other coolant voids the warranty. (Page 3)
4
How do I thread welding wire through the Spoolmatic 30A?
Loosen the thumbscrew, remove the canister cover, then lift the pressure roll arm and open the pressure roll assembly. Thread the wire through the canister inlet guide, along the drive roll groove, and out the contact tube, installing the spool so the wire feeds off the bottom. Close and secure the pressure roll assembly, then reinstall the top cover and canister cover. (Page 10)
5
What should I do if the welding wire feeds erratically?
Check and correct the drive roll pressure, then clean or replace the drive roll if needed. You should also decrease the spool brake pressure if it is set too tight. These remedies are outlined in the troubleshooting table. (Page 14)
6
What is the recommended routine maintenance schedule for the Spoolmatic 30A?
Before each use, check gun parts for looseness, cracks, and breaks, and clean weld spatter from around the nozzle opening using a hardwood stick — never a metal tool. Every three months, repair cable insulation damage and clean and tighten gun cable and work clamp connections. Every six months, remove the outer enclosure and blow out or vacuum dust and dirt from inside using a clean, dry airstream or vacuum suction. (Page 18)
Show 4 more questions
How do I adjust the drive roll and spool brake pressure?
What should I do if pressing the gun trigger does not energize the weld control or start shielding gas flow?
What is the ampere rating difference between the air-cooled and water-cooled models?
How do I change the contact tube and liner on the Spoolmatic 30A?
Full Manual
27 pages
Page 1
February 1992
Form: Om-1213B
Millerfi Effective With Serial No. KC184391Model:
SPOOLMATICfi30A SPOOLMATICfi30WOwnerS Manual
IMPORTANT: Read and understand the entire contents of both this manual and the power source manual used with this unit, with special emphasis on the safety MILLER ELECTRIC Mfg. Co. material throughout the manual, before installing, operating, or maintaining this A Miller Group Ltd., Company equipment. This unitand these instructions are for use only bypersons trained and P.O. Box 1079 experienced in the safe operation of welding equipment. Do not allow untrained persons to install, operate, or maintain this unit. Contact your distributor ifyou do Appleton, WI54912 Usa
Tel. 414.734.9821 not fully understand these instructions. cover2 1/92 Ref. SB-147 741-APrinted In Usa
Page 2
I
I
:I~iLimited Warranty
Effective: August 6, 1990
This 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 hereof, MILLER Electric Mfg. Co. Appleton. Wisconsin war rants to its Distributor/Dealer that all new and unused Equipment furnished byMiller
is free from defect in workmanship and material as of the time and place of delivery by MILLER. No warranty is made by MILLER with respect to engines, trade accessories or other items manufactured by others. Such engines, trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any. All engines are warrantied by their manufacturer for two years from date of original purchase, except Deutz engines which have a one year, 2000 hour warranty. In the case of MILLERs breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be, at MILLERs option (1) repair or (2) replace ment or, where authorized in writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized MILLER 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. MILLERs option of repair or replacement will be FOB., Factory at Appleton, Wisconsin, or FOB. at a MILLER authorized service facility, therefore, no compensation for transportation costs of any kind will be allowed. Upon receipt of notice of apparent defect or failure, MILLER shall instruct the claimant on the warranty claim procedures to be followed. Except as specified below, MILLERs warranty does not apply to components having normal useful life of less than one (1) year, such as spot welder tips, relay and contactor points, MILLERMATIC parts that come in contact with the welding wire including nozzles and nozzle insulators where failure does not result from defect in workmanship or material. MILLER shall be required to honor warranty claims on war ranted Equipment in the event of failure resulting from a defect within the following periods from the date of delivery of Equipment to the original user:Any Express Warranty Not Provided
Herein
And Any Implied Warranty, Guaranty Or Repre
Sentation As To Performance, And Any Remedy
For Breach Of Contract Which,
But For
This
Provision, Might Arise By Implication, Operation
Of Law, Custom Of Trade Or Course Of Dealing,
Including
Any
Implied Warranty
Of Merchan
Tability Or Of Fitness For Particular Purpose,
With
Respect
To
Any
And
All
Equipment
Furnished By Miller Is Excluded And Disclaimed
By Miller.
Except
As
Expressly
Provided
By
Miller
In
Writing,
Miller
Products
Are
Intended
For
Ultimate
Purchase
By
Commercial/Industrial
Users And For Operation
By Persons Trained
And Experienced In The Use And Maintenance Of
Welding Equipment And Not For Consumers Or
Consumer
Use.
MillerS
Warranties
Do
Not
Extend To, And No Reseller
Is Authorized To
Extend MillerS Warranties To, Any Consumer,
Receiving-Handling
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers Transportation Department. When requesting information about this equipment, always provide Model Designation and Serial or Style Number. Use the following spaces to record Model Designation and Serial or Style Number of your unit. The information is located on the rating label or nameplate. Model __________ Serial or Style No. Date of Purchase r~,iIIe, 8/91 Page 3
Errata Sheet
July 15, 1992Form: Om-1213B
aCaution
Use above FORM number when ordering extra manuals. INCORRECT COOLANT OR COOLANT CONTAINING STOP-LEAK ADDITIVES can corrode and/or plug gun! feeder cooling passages. Use only a mix of 50% distilled water and 50% high quality automotive antifreeze as proper coolant for this product. Do not use antifreeze containing stop-leak additives. Use of other coolant voids warranty.Changes To Section 2 Specifications
Change the following entry in Table 2-1. Gun/Feeder aWarning
Welding
Wire
can cause puncture wounds. Do not 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. . ~i- . ELECTRIC SHOCK can kill. ,~S
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. After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in this manual. Specifications Description Coolant Requirements (Water-Cooled Models) 1 qt/min Minimum Flowrate Use Only 50% Distilled Water And 50% High Quality Automotive Antifreeze (See Section 3-8)Changes To Section 3 Installation
Replace Section 3-3. Adjusting Shielding Gas NozzleHot Surf
Allow gun to ACES can burn skin. cool before touching. w~warn2.I / w~warn71* 9/91 contact tube should be flush with end of nozzle. 2 Jam Nut 3 Shielding Gas Nozzle To change contact tube location, loosen jam nut, and turn nozzle. Tighten jam nut.5T.1 50434
Figure 3-3. AdJusting Gas Nozzle Page 4
Change Section 3-8. Coolant Guidelines To Minimize Corrosion Minimize corrosion in the gun/feeder and cooling system by following these guidelines: 1 .- Use only a mix of 50% distilled water and 50% high quality automotive antifreeze that does not contain stop-leak additives. Use of other coolant voids the warranty.
Changes To Section 5 Maintenance And Troubleshooting
Add the following to Table 5-2. Welding Trouble Trouble Remedy Section Poor cleaning action when Position contact tube within nozzle. 3-3 weldin g aluminum.L_
Amend Parts List as follows: Figure 6-1. Circuit Diagram For Gun/FeederI
Part Replaced No. With Description Quantity 17- Added ... 134 799 .. 0-RING, .176 ID x .070 CS (30A model only) (Effw/KC224994) (used w/thumbscrew) 1 17- .... 134 799 ... 134 799 .. 0-RING, (qty chg) (30W model only) (Effw/KC224994) (Additional qty used w/thumbscrew) 3 18-38 ... 133 083 ... 154 307 .. SPRING, tension adj drive roll (Eff w/KC243471) 1 18-53 .. . 135 498 ... 155 565 .. SCREW, thumb spring plunger (Effw/KC194049) 1 **First digit represents page no digits following dash represent item no.Be Sure To Provide Model And Serial Number When Ordering Replacement Parts.
OM-l2l3BPage2Pull
Motor
62Changes To Section 6 Electrical Diagrams
I-
Gun
Assembly
~1 CwTrigger
-o oPb
I
) ~B
C
\V
0Y
Cord
#1 \!/G
E
\!/F
Changes To Section 7 Parts List
Plg2
Y
Cord
#2 )Sa.136 956-B
Page 5
Arc Welding Safety Precautions
ELECTRIC SHOCK can kill. Touching live 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.Warning
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAway. Pacemaker Wearers Keep Away Until Consulting Your Doctor.
In-welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed on the next page. Read and follow all Safety Standards. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BYQualified People.
Ll~.
Arc Rays
can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.A~
Page 6
CYLINDERS can explode if damaged. 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 sure to treat them carefully.
To Explode;
Battery Acid
can burn eyes and skin. Batteries contain acid and generate explosive gases.Steam
And
Pressurized
Hot
COOLANT can burn face, eyes, and skin. The coolant in the radiator can be very hot and under pressure. ENGINES can be hazardous. Always wear a face shield when working on a battery. Stop engine before disconnecting or connecting battery cables.Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1. from American Welding Society, 550 NW. LeJeune Ad, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superinten dent 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, Amen. can Welding Society Standard AWS F4.1,from American Welding So ciety, 550 NW. LeJeune Ad, Miami, FL 33126 National Electrical Code, NFPA Standard 70, from National Fire Pro tection Association, Batterymarch Park, Quincy, MA 02269. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-I, from Compressed Gas Association, 1235 Jefferson Davis High way, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, CSA Standard Wi 17.2. from Canadian Standards Association, Standards Sales, 178 Rexdale Bou levard, Rexdale, Ontario, Canada M9W1 R3.
Safe Practices ForOccupationAnd Educational Eye And Face Protec tion, ANSI Standard Z87.1, from American National Standards Insti tue. 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51 B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. aWarning
ENGINE EXHAUST GASES can kill.Engine
Fuel
can cause fire or Page 7
Table Of Contents
Section
1 Safety Signal Words
1Section 2 Specifications
2-1. DutyCycle 1Section 3- Installation
3-1. Removing Top Cover 2 3-2. Installing Wire Spool And Threading Welding Wire 2 3-3. Adjusting Shielding Gas Nozzle 3 3-4. Rotating Canister 4 3-5. Connecting Air-Cooled Model To Weld Control 4 3-6. Connecting Water-Cooled Model To Weld Control 5 3-7. Installing Gas Supply 6 3-8. Coolant Guidelines To Prevent Corrosion 7 3-9. Adjusting Drive Roll And Spool Brake Pressure 7Section 4Operation
8Section 5 Maintenance & Troubleshooting
5-1. Routine Maintenance 10 5-2. Changing Contact Tube And LinerSection 6 Electrical Diagrams
15Section 7 Parts List
Figure 7-1 Main Assembly 16Om-1213B -2/92
Page 9
Section 1
Safety Signal Words
modl.l 9191 The following safety alert symbol and signal words are used throughout this manual to call attention to and identity different levels of hazard and special instructions. aWarning
WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life. aCaution
CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment. ~ IMPORTANT: statements identify special instructions necessary for the most efficient operation of this equipment.Section 2
Specifications
Table 2-1. Gun/Feeder Specification Description Input Power 30 Volts DC Ampere Rating Air-Cooled Models: 200 Amperes; Water-Cooled Models: 400 Amperes Duty Cycle 100% Using Argon Shielding Gas (see Section 2-1) Approximate Wire Feed Range 70 to 875 pm (1.7 to 22.2 mpm) Wire Diameter Range .025 Thru 1/16 in. (0.6 Thru 1.6 mm) Aluminum Wire .025 Thru .045 in. (0.6 Thru 1.1 mm) Hard Or Cored Wire Maximum Spool Size 4 in. (102 mm) Diameter Cooling Method Air Cooled (A Models) Or Water Cooled (W Models) Coolant Requirements (Water-Cooled Models) 1 qt./min. Minimum Flowrate Use Distilled Or Deionized Water, Or High-Quality Tap Water Cable Length 30 ft. (9.1 mm) Overall Dimensions Length: 15-3/8 in. (390 mm); Width: 2-1/2 in. (64 mm); Height: 10-3/4 in. (273 mm) Weight Air-Cooled Models: Gun Only 2.9 lbs. (1.3 kg); Gun With Cable Assembly 14 lbs. (6.4 kg) Water-Cooled Models: Gun Only 3.4 lbs. (1.5 kg); Gun With Cable Assembly 14.5 lbs. (6.6 kg) 2-1. Duty Cycle Duty cycle is how long the gun/feeder can operate within a ten minute period without causing overheating or damage. This gun/feeder is rated at 100% duty cycle allowing continuous operation when using argon shielding gas. OM-1213 Page 1 Page 10
Section 3Installation
Table 3-1. Items Included With Gun/Feeder *Contact tubes are marked with wire size and inside diameter (LD.) of tube. Forex ample, a .035/52 contact tube is used with .035 wire, and the tube has an ID. of 0.052 in. (1.3 mm).~ Important:
If contact tube, liner, and drive rot/groove are not correct for wire size and type, see Section 5 to change parts as needed. See Section 7 for list of other available contact tubes. 3-1. Removing Top Cover Figure 3-1. Top Cover 3-2. Installing Wire Spool And Threading Welding Wire 41 WARNiNG CYLINDERS can explode It damaged. Keep cylinders away from welding and other electrical circuits. Never touch cylinder with welding electrode. Always secure cylinder to running gear, wall, or other stationary support. Item Quantity Drive Roll (Small Groove For .025 To .035 in. Wire, Large 1 Groove For .047 To .062 in. Wire) Shipped With Large Groove In Feed Position Contact Tubes* (1 For Each Wire Size .0231.025, 5 .030, .035, .0451.047, And .062 in.) Shipped With .0451.047 Installed Liner (1 .023-035 AndI
.047-062 in.) Shipped With 2 .045-062 Installed 10 ft. (3 m) Gas Hose With Adapter Fitting 1 10 ft. (3 m) Water Hose With Adapter Fitting (Water-Cooled Models Only) lOft. (3 m) Water Hose (Water-Cooled Models Only) 1 Contact Tube Wrench 1 1 Top Cover Push back and lift off as shown. To reinstall cover, set rear of cover in gun/feeder, and push cover back and down until it clicks into posi tion. Ret. ST.150 882-A 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.Welding Wire
can cause puncture wounds.Hot Surf
Allow gun to ACES can burn skin. cool before touching. Do not 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. 7~ wfwarn2.1 /wfwarnl.t 9/91 OM-1213 Page 2 Page 11
Figure 3-2. Installing Spool And Threading Wire 3-3. Adjusting Shielding Gas Nozzle a
Warning
ELECTRIC SHOCK, WELDING WIRE, AND HOT PARTS HAZARDS. Read safety infor mation at beginning of Section 3-2 before proceeding. 1 3 Shielding Gas Nozzle To change contact tube location, loosen jam nut, and turn nozzle. Tighten jam nut. 3St-Iso 434
0 3 4 9 1 Top Cover 2 Canister 3 Canister Cover 4 Thumbscrew Loosen thumbscrew and remove cover. 5 Wire Spool Loosen wire from spool, cut off bent wire, and pull 6 in. (150mm) of wire off spool. 6 Pressure Roll Assembly Lift arm and open pressure roll as sembly. 7 Canister Inlet Guide 8 Drive Roll Groove 9 Contact Tube Thread wire through canister inlet guide, along drive roll groove, and out contact tube. Install spool so wire feeds off bot tom. 10 Spool Brake Thumbnut If necessary, turn thumbnut coun terclockwise slightly to install spool. Close and secure pressure roll as sembly. Reinstall top cover and canister cover.5T.150 436-A
Tools Needed: 2~ Figure 3-3. Adjusting Gas Nozzle OM-1213 Page 3 Page 12
3-4. Rotating Canister 3-5. Connecting Air-Cooled Model To Weld Control ~
Warning
ELECTRIC SHOCK can kill. Do not touch live electrical parts. Turn OFF welding power source, and disconnect input power before inspecting or installing. Stop engine on welding generators. Swami i9/91A.
Connections To 24 Volt Weld Control Figure 3-5. Connections To 24 Volt Weld Control 1 Canister Move canister until it clicks into one of the 5 positions shown.St-150 433-A
Rear View Figure 3-4. Rotating Canister 2 4 1 Gas Hose 2 lOft. (3m) Gas Hose With 5/8 in. Adapter Fitting Connect fitting to gun/feeder gas hose and remaining end to regula. tor/flowmeter (see Section 3.7). 3 24 Volt Weld Control 4 Trigger Control Cord Insert plug into receptacle, and tighten threaded collar. 5 Weld Cable Connect to positive (+) weld output terminal on welding power source according to its Owners Manual.St-150 917-A
Tools Needed: 1-1/8 in., 5/8 in. OM-1213 Page 4 Page 13
B.
Connections To 115 Volt Weld Control Tools Needed: ~ 1-1/8 in., 5/8 in. 1 115 Volt Weld Control 2 Gas Hose Connect to Gas outlet on control. 3 lOft. (3m) Gas Hose Remove 5/8 in. adapter fitting from hose. Connect according to weld control Owners Manual. 4 Trigger Control Cord Insert plug into receptacle, and tighten threaded collar. 5 Weld Cable 6 Positive (+) Weld Output Terminal In Control Connect weld cable to positive (+) weld output terminal in weld control. Reinstall weld control wrapper. Ret. ST.1 49549-A / ST-I 49966-A Figure 3.6. Connections To 115 Volt Weld Control 3-6. Connecting Water-Cooled Model To Weld Control 4~Warning
ELECTRIC SHOCK can kill. Do not touch live electrical parts. Turn OFF welding power source, and disconnect input power before inspecting or installing. Stop engine on welding generators. OVERHEATING can damage gun parts. If using recirculating coolant system, do not make connections from coolant system to water valve; instead make connections directly from coolant system to gun hoses.Incorrect
Coolant
Flowrate
can damage gun parts. Maintain minimum lqt/min. flowrate at all times. swamI.19/91
3~, 5 4A.
Connections To 24 Volt Weld Control 4 Obtain coolant supply.I
Trigger Control Cord 2 24 Volt Weld Control Insert plug into receptacle, and 5 tighten threaded collar. 3 Power(Water Cable 4 Power Cable Adapter 5 loft. (3m) Water Hose Obtain Power Cable Adapter kit 139 161 and connect according to kit instructions. 6 Gas Hose 7 10 ft. (3m) Gas Hose With 5/8 in. Adapter Fitting Connect fitting to gun/feeder gas hose and remaining end to regula. tor/flowmeter (see Section 3.7). 8 Water Hose 9 10 ft. (3 m) Water Hose With 5/8 in. Adapter Fitting Connect fitting to gun/feeder water hose and remaining end to water supply.St-150 432-9
2 Tools Needed: ~ 1-1/8 in., 5/8 in. Figure 3-7. Connections To 24 Volt Weld Control OM-1213 Pages Page 14
B.
Connections To 115 Volt Weld Control 3-7. Installing Gas Supply aWarning
I
~T~
-b-- ~ ~ c YLINDERS can explode it damaged. Keep cylinders away from welding and other electrical circuits. Never touch cylinder with welding electrode. Always secure cylinder to running gear, wall, or other stationary support. \ 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. wfwarnl.1 9/91 Obtain gas cylinder and chain to running gear, wall, or other station ary support so cylinder cannot fall and break off valve. 1 Cylinder 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 Cap 4 Regulator Obtain regulator and install onto gas cylinder so that face is vertical. 5 Flow Gauge Obtain flow gauge. 6 Flow Adjust 7 Typical flow rate is 20 cfh (cubic feet per hour). 7 Gas Hose Connection .~ Tools Needed: Fitting has 5/8-18 right-hand ~ 1-1/8 in., threads. Connect gas hose fitting ~ 5/8 In. here. Ref. ST.149 827 Figure 3-9. Typical Argon Regulator/Flow Gauge Installation Obtain coolant supply. 1 115 Volt Weld Control 2 Strain Relief Remove strain relief as shown. 3 Power/Water Cable Route cable through strain relief and connect to weld/water outlet on control. Reinstall strain relief. 4 Trigger Control Cord Insert plug into receptacle, and tighten threaded collar. 5 Water Hose Connect to water outlet on control. 6 Gas Hose Connect to gas outlet on control. 7 lOfi. (3 m) Water Hose 8 lOft.(3m)GasHose Remove 5/8 in. adapter fittings from hoses. Connect hoses ac cording to weld control Owners Tools Needed: Manual. ~ 1-1/8 in., 5/Bin.St-152 455
2 3 Figure 3-8. Connections To 115 Volt Weld Control OM-1213 Page 6 Page 15
3-8. Coolant Guidelines To Prevent Corrosion Prevent corrosion in the gun/feeder and cooling system by following these guidelines:
Caution
Welding Wire
can cause puncture wounds. Do not 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. HOT SURFACES can burn skin. Allow gun to cool before touching. Figure 3-10. AdJusting Drive Roll And Spool Brake Pressure w~warn2.1 9/91 3 6 1 Top Cover 2 Canister Cover 3 Thumbscrew Loosen thumbscrew and remove cover. 4 Spool Cut welding wire off at contact tube. Retract wire onto spool and secure. 5 Spool Brake Thumbnut Grasp spool in one hand and turn while adjusting spool brake thumb- nut. When a slight force is needed to turn spool, tension is set. Do not overtighten. Reinstall canister cover. Thread welding wire (see Section 3-2). 6 Drive Roll Tension Thumbnut 7 Adjusting Pressure Turn ON unit and check drive roll pressure by feeding wire against a wood board or concrete surface; wire should feed steadily without slipping. Adjust drive roll tension thumbnut if necessary. Do not overtighten. Turn OFF unit. Reinstall top cover. Ref. 5T.151112/S.0651
Tools Needed: OM-1213 Page 7 Page 16
Section 4- Operation
aWarning
ELECTRIC SHOCK can kill. Do not touch live electrical parts. Always wear dry insulating gloves. Insulate yourself from work and ground. Keep all panels and covers securely in place FUMES AND GASES can be hazardous to your health. Keep your head out of the fumes. Ventilate area, or use breathing device. Read Material Safety Data Sheets (MSDSs) and rers instructions for material used 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. Allow work and equipment to cool before handling. p ~ ~.Arc
Rays
can burn eyes and skin; NOISE can damage hearing. Wear welding helmet with correct shade of filter. Wear correct eye, ear, and body protection. ' MOVING PARTS can cause injury. Keep away from pinch points such as drive rolls. Keep all doors, panels, covers, and guards closed and securely in place.I
~L_
Magnetic Fields From High Cur
RENTS can affect pacemaker operation. Pacemaker wearers keep away. Wearers should consult their doctor before going near any welding operations. See Safety Precautions at beginning of manual for ba. sic welding safety information. ~arn3 1 10/91 1 Insulating Gloves 1 2 3 / ~~ 2 Safety Glasses With Side Shields 3 Welding Helmet Wear dry insulating gloves, safety glasses with side shields, and a welding helmet with a correct shade of filter (see ANSI Z49.1). sb3.1 10/91 Figure 4-1. Safety Equipment 1 Work Clamp 1~ Use wire brush or sandpaper to clean metat at weld joint area. Connect work clamp to a clean, paint.free location on workpiece, as close to weld area as possible. 2 Voltage Sensing Cable Clamp For 115 volt weld controls only, Tools Needed: ~ connect to work clamp for constant current (CC) operations (see weld control Owners Manual). sb4.1 10/91 Ref. 50144 451.A Figure 4-2. Work And Voltage Sensing Cable Clamps OM-1213 Page 8 Page 17
Figure 4-3. Controls
I_____________________________________________________________________
Shut off shielding gas supply when not in use. warnl.1 9/91 1 Shielding Gas Cylinder 2 Valve 3 Gun Trigger Open valve on cylinder just before welding. Purge air from gas line by !ightly pressing gun trigger. Close valve on cylinder when fin. shed welding. sb5.1 1/92 S-0821-C I Ref. S8-i47 741.A 1 s 1 Coolant Supply Turn on coolant supply before welding. Turn off coolant supply when fin ished welding. ,-~. ~~ e~e°O°
fi Rłf. ST150 755 -_.- Figu re 4-5 . Coo lant Supply For Water-Cooled Models Only Install & )) Put On \ ) Set Controls ) SetCon~y\ Turn On Gas )~noD~ And WaterI
Connect Personal Safety On Weld Control On Gun/Feeder ) (If Applicable) ) Equipment Equipment J ________________ ________________ ________________ ) Do \ Readjust Controls Sample Weld 1 And Prepare}J
For Productionj 1 Trigger Press trigger to energize welding power source contactor (if applica ble), start shielding gas flow, and begin wire feed. For shielding gas preflow and post- flow, lightly press trigger before and after welding. 2 Trigger Hold Button Use button to continually feed wire without holding down the trigger. Press button while pressing the trigger, release trigger, and wire continues to feed until trigger is pressed again. 3 Wire Speed Control Use control to adjust wire feed speed. The numbers in the opening are not a wire feed speed and are for reference only. Ref. SB-147 741-A BUILDUP OF SHIELDING GAS can harm health or kill. Figure 4-4. Shielding Gas Figure 4-6. Sequence Of Gas Metal Arc Welding (GMAW) Page 18
Section 5 Maintenance & Troubleshooting
Aa
Warning
ELECTRIC SHOCK can kill. Do not touch live electrical parts. Turn OFF wire feeder and welding power source, and disconnect input power before inspecting, maintaining, or servicing. Stop engine on welding generators., MOVING PARTS can cause injury. Keep away from moving parts. Keep away from pinch points such as drive rolls. HOT PARTS can cause severe burns. Allow cooling period before servicing gun or unit. ance to be performed only by qualified w~warn41* 9/91 Maintenance Table 5-1. Maintenance Schedule 3 Figure 5-1. Changing Contact Tube And Liner 5-1. Routine Time Maintenance Before each use Check gun parts for looseness, cracks, and breaks; tighten, repair, and replace parts as re quired. Carefully clean weld spatter or dirt from~round nozzle opening using a hardwood stick, never a metal tool. Every month Above normal equipment use: Repair any damaged insulation or replace gun cable or work cable, clean internal parts (see 6 month entry), clean and tighten connections at gun cable and work clamp. Every 3 months Repair cable insulation damage or replace gun cable or work cable. Clean and tighten gun cable and work clamp connections. Every 6 months Remove unit outer enclosure to blow out or vacuum dust and dirt from inside using a clean, dry airstream or vacuum suction. 5-2. Changing Contact Tube And Liner aWarning
Electric Shock, Moving Parts, And Hot Parts H
mation at beginning of Section 5 before proceeding. AZARDS. Read safety infor Turn OFF weld control and welding power source. , Remove top cover and open pres sure roll assembly as shown in Figure 5-2. 1 Contact Tube Wrench Insert wrench into nozzle over con tact tube. 2 Compression Nut Loosen nut. Pull out contact tube. 3 Contact Tube 4 Nozzle Pull wire out nozzle and liner should slide out. If necessary, tilt 4 nozzle down to remove liner. Close pressure roll assembly. Re install top cover. Install new liner and contact tube Tools Needed: over wire. Cut off wire at end of con tact tube. Tighten nut just until contact tube is secure. Overtightening nut will damage adapter.St.150 437
OM-1213 Page 10 Page 19
5-3. Changing Or Cleaning Drive Roll a
Warning
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor mation at beginning of Section 5 before proceeding. Use wire brush to clean drive roll. Install drive roll with desired groove down, and turn drive roll so one set screw faces flat side of shaft. 7 Bearing 8 Liner Line up drive roll groove with bear ing groove and liner opening. Tigjit en setscrews. Thread welding wire (see Section 3-2). Adjust drive roll pressure, if necessary (see Section 3-9). Close and secure pressure roll as sembly. Reinstall top cover. 5-4. Replacing Or Cleaning Drive Roll Bearing aWarning
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety Infor mation at beginning of Section 5 before proceeding. Turn OFF weld control and welding power source. 1 Top Cover 2 Pressure Roll Assembly Cut oft wire where it enters pres sure roll assembly area. 3 Setscrew 4 Current Pick-Up Tab This tab helps prevent burnback caused by welding arcs inside the contact tube. This tab may be re moved to provide an insulated drive roll. (If tab is removed, a smaller diameter contact tube is recommended. See options in Parts List.) Lightly grease top of tab before reinstalling. 5 Motor Shaft 6 Drive Roll Tools Needed: 5/16 in. Figure 5-2. Removing Drive Roll Pet. ST-t49 967-A Figure 5-3. Removing Drive Roll Bearing OM-1213 Page 11 Page 20
5-5. Replacing Canister Inlet Guide a
Warning
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor mation at beginning of Section 5 before proceeding. 5-6. Replacing Spool Canister aWarning
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor mation at beginning of Section 5 before proceeding. 7 Turn OFF weld control and welding power source.I
Top Cover 2 Pressure Roll Assembly Cut oft welding wire where it enters pressure roll assembly area. 3 Nozzle Pull wire out nozzle. 4 Thumbscrew 5 Canister Cover Loosen thumbscrew and remove cover. 6 Wire Spool 7 Spool Brake Thumbnut Loosen thumbnut, retract wire onto spool, secure, and remove spool. 8 Canister Inlet Guide Turn counterclockwise to remove. Install new guide. Reinstall spool and thread welding wire (see Section 3-2). Adjust spool brake pressure and drive roll pressure if necessary (see Section 3-9). Close pressure roll assembly. Re install canister cover and top cover. Ref ST-i 50436/Ret. ST-149 967 8 Tools Needed: Figure 5-4. Removing Canister Inlet Guide 1 2 Turn OFF weld control and welding power source. 1 Top Cover 2 Pressure Roll Assembly Cutoff welding wire where it enters pressure roll assembly area. 3 Nozzle Pull wire out nozzle. 4 Spring Plunger Thumbscrew Turn thumbscrew counterclock wise three full turns. 5 Spool Canister Remove as shown. Push new can ister into wire drive housing until fully seated. Tighten thumbscrew. Install spool and thread welding wire (see Section 3-2). Adjust spool brake pressure and drive roll pressure as necessary (see Section 3-9). Close pressure roll assembly. Re install top cover and canister cover. Ref. ST-i 49 967 Tools Needed: Figure 5-5. Removing Canister OM-1213 Page 12 Page 21
5-7. Replacing Contact Tube Adapter
A.
Air-Cooled Models aWarning
ELECTRIC SHOCK, MOVING PARTS, AND HOT PARTS HAZARDS. Read safety infor mation at beginning of Section 5 before proceeding. Figure 5-6. Removing Contact Tube AdapterB.
Water-Cooled Models aWarning
WATER IN GUN PARTS can cause ELECTRIC SHOCK and can lower weld quality. Turn OFF welding power source and water supply before working on gun. Stop engine on welding generators. Always point gun downward when removing water-cooled barrel to keep water out of gun parts. Wipe gun dry before putting it back together. Turn OFF weld control and welding power source. 1 Nozzle 2 Nozzle Adapter Remove as shown. 3 Contact Tube Adapter Use wrench to remove adapter. Tools Needed: Coat new adapter with threadlock. ing compound (such as Loctite No.F ~
242) and install.St-Iso 431
Figure 5-7. Removing Contact Tube Adapter 5-8. Troubleshooting 4~Warning
ELECTRIC SHOCK can kill. Do not touch live electrical parts. Turn OFF welding power source, and disconnect input power before inspecting, maintaining, or servicing. Stop engine on welding generators. ,.~~M
OVING PARTS can cause Injury. Keep away from moving parts. Keep away from pinch points such as drive rolls. Troubleshooting to be performed only by qualified persons. Swarn9.2 10/91 6 5 4 Turn OFF weld control and welding power source. 1 Barrel Extension Remove as shown. 2 Contact Tube 3 Compression Nut To remove, see Section 5-2. 4 Contact Tube Adapter 5 Head Tube 6 Head Tube Setscrew Loosen setscrews and remove adapter. Install new adapter and tighten set screws. Reinstall contact tube, compression nut, and nozzle.St.150 430-A
Tools Needed:F
~~~ 3/32 in. HOT PARTS can cause severe burns. Allow cooling period before or servicing gun or unit. OM-1 213 Page 13 Page 22
Table 5-2. Welding Trouble Trouble Remedy Section No weld output; gun/feeder does not work. Secure weld control pug in 115 volts ac receptacle. Place POWER switch on welding power source in the ON posi tion. Erratic weld output. Tighten and clean all connections. Pressing gun/feeder trigger does not energize weld control; welding wire is not energized; shielding gas does not flow. Secure plug from gun/feeder trigger cord into 10-socket recep- tacle on weld control. 3-5 Wire does not feed; burnback in contact tube. Reinstall current pick-up tab if applicable. 5-3 Wire feeds, shielding gas flows, but welding wire is not energized. Secure contact control cable leads in weld control (see weld control Owners Manual). See Troubleshooting section in welding power source Owners Manual. Wire feeds erratically. Check and correct drive roll pressure. Clean drive roll or replace drive roll. Decrease spool brake pressure. 3-9 5-3 3-9 Gun overheating (Water-cooled Models). Be sure coolant flowrate is at least 1 qt./min. Corrosion buildup in gun/feeder decreasing coolant flowrate. Backflush coolant system, clean coolant system filter, and clean fittings. . 3-8 OM-1213 Page 14
Page 23
Section 6
Electrical Diagrams
Figure 6-1. Circuit Diagram For Gun/FeederSb-139 060-A
Pull
Motor
Gun
Assembly
L_
Trigger
-o oPb
I
/D
J
~B
C
A
CwF
I
Sa-138 956-A
V
Cord
#1G
H
Plg2
E
V
Cord
2Housing
Figure 6-2. Wiring Diagram For Gun/Feeder OM-1213 Page 15 Page 24
93~ 92 91 90 89 71 *Inctudes Item 55 & 69 67 66 65 64 40 63
St-143
116-B
0C~) -U
cD 0) 9 10 7 31 3233 34 35 36 108 44 106 46 105 47 55 56 57 58 52 51 (I) ii C) -I 0 z -4 -I Cl) r Cl)-l 50 56 62 Figure 7-1. Main Assembly Page 25
.2 19 20 21 22 23 23 24 26 27 28 28 29 30 31 32 33 34 35 133479 135196 133362 137475 137472 056851 010607 010606 056108 134834 089 120 057 020 000 571 056 851 010 607 056 108 134 834 048 837 010 603 010 606 056 112 603 106 000 950 138 459 146 212 138 033 053 212 137 477 073 476 137 479 600 722 600318 127 893 152 577 137 495 141 694 058 685 602 172 136 730 134 800 132 985 134 799 152 579 152 578 133 365 000 417 143 836 008 033 604612 602 169 136 135 602 066 602 198 146 558 132 270 134 624 134 623 132 852 Figure 7-1. Main Assembly Item Dia. Part No. Mkgs. No. Description Quantity .8 10 . 11 . 12
Plg2
13 14 15 16 17 18..Cover
1 SPRING, closure cover 1 STRAIN RELIEF, cable 1 HOSE, water in (30W model only) (consisting of) 1 HOSE, gas in (consisting of) 1 FITTING, hose brs barbed nipple 3/l6tbg 1 FITTING, hose brs nut .625-18LH (water hose) 1 FITTING, hose brs nut .625-18RH (gas hose) 1 FITTING, hose brs ferrule .425 ID x .718 Ig 1 HOSE, SAE .187 ID x .410 OD (order by ft) 31ft CLAMP, hose .375-.450c1p dia slfttng 1 FITTING, hose brs coupler .625-18LHI.625-18LH (30W model only) 1 HOSE, water (30W model only) (consisting of) 2 FITTING, hose brs barbed nipple 3/l6tbg 2 FITTING, hose brs nut .625-18LH 2 FITTING, hose brs ferrule .425 ID x .718 Ig 2 HOSE, SAE .187 ID x .410 OD (order by ft) lOft HOSE, gas (consisting of) 1 FITTING, hose brs barbed nipple 1/4tbg 2 FITTING, hose brs nut .625-18RH 2 FITTING, hose brs ferrule .475 ID x .718 Ig 2 HOSE, nprn brd No. 1 x .250 ID (order by ft) lOft FITTING, hose brs coupler .625-18RH/.625-18RH 1 CABLE, control (consisting of) 1 PLUG, 10 pin MS-3106A-18-1PX 1 CLAMP, cable 97-3057-1010 1 CABLE, port No. 18 4/c (order by ft) 63ft CABLE, power/water out 30ft (30W model only) 1 CLAMP, strap rbr 5 holes .375 wide x 4.625 Ig 13 CABLE, power (30A model only) (consisting of) 1 TERMINAL, ring tng .500 stud No. 4 cable 1 CABLE, weld cop strd No.3 (order by ft) 31ft RING, crimp cable 1 STRIP,cop.010x2.000x.750 1 FITTING, connection power weld (30A model only) 1 SCREW, set stl sch .312-18 x .375 cone point (30A model only) 1 NUT, jam nozzle extension (30A model only) 1 SCREW, set stl sch 10-32 x .187 cup point (30A model only) 1 ADAPTER, tube head (30A model only) 1 0-RING, .614 ID x .070 CS 2 MANIFOLD, water (30W model only) 1 0-RING, .176 ID x .070 CS (30W model only) 2 HOUSING, wire drive (XR-A models only) (Includes Items 55 & 69) ... 1 HOUSING, wire drive (XR-W models only) (Includes Items 55 & 69) ... 1 CLAMP, headtube 1 SCREW, cap stl sch 10-24 xl .000 2 SPRING, cprsn .445 OD x .023 wire x .370 1 WASHER, flat felt .234 ID x .500 OD x .O93thk 1 SCREW, set stl sch 8-32 x .125 cup point (30A model) 4 SCREW, set stl sch 8-32 x .187 cup point (30W model) 1 ROLL, drive VK groove .023-1/16 wire 1 SCREW, mach stl trh 6-32 x .250 3 WASHER, lock stl split No. 6 1 KIT, current pick-up contact 1 SCREW, mach stl rdhph 6-32 x .500 1 BEARING, fig nyl .140 ID x .187 OD x .375f1g x .O3lthk 2Bearing
1 ARM, pressure 1 OM-1213 Page 17 25 36 Page 26
Description Quantity Figure 7-1. Main Assembly (Continued) Item Dia. No. Mkgs. Part No. .. 37 605 798 .. WASHER, shldr nyl .375 OD x .168 ID x .080 2 .. 38 133 083 .. SPRING, tension adj drive roll 1 .. 39 144 860 .. SCREW, mach sti flh 8-32 x .437 1 .. 40 058 968 .. RING, retainer E 2 .. 41 135474 .. PIN, hinge 1 .. 42 602 209 .. WASHER, lock stl intl tooth .250 1 . 43 132 530 .. SCREW, mach sti phtrh .250-20 x .500 1 . 44 132 527 .. CANISTER, spool 1 . 45 148 488 .. POST, support spool 1 .. 46 132 529 .. PAD, brake 1 .. 47 148 489 .. WASHER, anti-turn 1 .. 48 132 524 .. NUT, thumb brake 1 .. 49 000 364 .. RING, retainer ext .188 shaft x .O2Sthk 1 .. 50 132 528 .. SCREW, thumb canister 1 .. 51 132 526 .. COVER, spool 1 . 52 132 521 . . GUIDE, inlet canister 1 .. 53 135 498 .. SCREW, thumb spring ptunger 1 . 54 135 126 .. SCREW, set stl sch 6-32 x .125 cup point 1 .. 55 135 580 .. FITTING, gas (30A model) 1 .. 55 135 580 .. FITTING, gas (30W model) 2 .. 56 112 896 .. SPRING, cprsn .240 OD x .020 wire x .437 2 . 57 135 773 .. NUT, thumb tension adjusting 8-32 1~ .. 58 602 082 .. SCREW, mach stl rdh 8-32 x .500 1 .. 59 604 638 .. SCREW, cap stl sch 6-32 x .375 3 60 136 128 .. CASE, gun LH 1 .. 61 135 646 .. SCREW, mach stl rdhph 8-32 x 1.500 2 62 135 896 .. PLUNGER, trigger hold 1 . 63 135 645 .. SCREW, mach sti rdhph 8-32 x .875 1 64 136 679 .. CLAMP, strain relief 1 65 132 269 .. SCREW, mach sti rdhph 8-32 x .375 1 66
B2
.. . . 134 248 .. MOTOR, gear PM 24VDC 42ORPH 10.2:1 ratio 1 67 133 373 ..Trigger
1 68 135 473 .. BUSHING, shaft motor 1 69 058 262 ..Cap
1 70 135 128 .. SCREW, cap stl sch 6-32 x 1 .000 (30W model only) 2 71 137 042 .. BARREL ASSEMBLY, water cooled (30W model only) (consisting of) . . 1 72 134800 .... 0-RING, .614IDx.O7OCS 2 73 136955 .... FITTING, endtubehead 1 74 136956 .... TUBE,head 1 75 136943 .... TUBING,teflon 1 .76 136834 .... WASHER,fbr.594IDx.8750Dx.l25thk 1 77 134 801 . . . . 0-RING, .926 ID x .070 CS 4 78 137 041 . . . . BARREL, outerI
79 136 836 . .. . INSULATOR, head tube from adapter 1 80 136 835 . . . . WASHER, flat brs .390 ID x .687 OD x .l25thk 1 81 136 680 ... . ADAPTER, contact tube 1 82 136 683 . . . . LINER, telfon .045-1/6 wire x 6.875 Ig 1 83 136 748 ... . NUT, compresson .375-24 1 84 135 424 ... . TUBE, contact .047-.061 wire 1 85 136 833 ... . NUT, jam adapter 1.000-8 1 86 136 832 . . . . ADAPTER, nozzle 1 050 622 . .. . NOZZLE, 5/8 orf x 1-5/8 Ig 1 87 oo~ 925 .. NOZZLE, spot outside corner .937 ID x 2.375 1 88 050 116 .. NOZZLE,13/16 orf x 1-5/8 Ig 1 89 050 115 .. NOZZLE, 1/2 orfx 1-5/Big 1 . 90 050 622 .. NOZZLE, 5/8 orf x 1-5/8 Ig 1 . . 91 ooo 442 .. NOZZLE, spot 1 OM-1213 Page 18 Page 27
Optional
Figure 7-1. Main Assembly (Continued)Be Sure To Provide Model And Serial Number When Ordering Replacement Parts.
Item Dia. Part No. Mkqs. No. Description Quantity . . 92 004 466 . . NOZZLE, spot 1 . . . 93 . 94 95 . 96 ooo 443 . 144 862 . 053 785 . 136 171 . . NOZZLE, spot inside corner . EXTENSION, nozzle (30A model only) . EXTENSION, barrel 2.875 Ig (30A model only) . TUBE, contact .025/31 wire 1 1 1 1 . 96 135 427 . . TUBE, contact .030/36 wire 1 . 96 135 428 . . TUBE, contact .030/41 wire 1 .. 96 147314 .. TUBE,contact.035/41 wire 1 96 135 430 . . TUBE, contact .035/52 wire 1 96 135 429 . . TUBE, contact .047/52 wire 1 96 135 424 . . TUBE, contact .047/61 wire 1 96 135 426 . . TUBE, contact .062/73 wire 1 96 135 425 . . TUBE, contact .062/81 wire 1 136 821 . . WRENCH, nut tube contact 1 . 97 98 98 99 100 101 . . .. R4
. . . 136 748 . 136 683 . 136 682 . 136 680 . 136 681 . . 137 854 . . NUT, compression .375-24 . LINER, teflon .045-1/16 wire x 6.875 Ig . LINER, teflon .023-035 wire x 6.875 Ig . ADAPTER, contact tube (30A model only) . TUBE, head (30A model only) . POTENTIOMETER, C sltd sft l/T .5W 10K ohm 1 1 1 1 1 1 . 102 144 861 . . WASHER, anti-turn 1 . . 103 104 105 602 169 . 134856.. 135 127 . . SCREW, set stl sch 8-32 x .187 cup pt. KNOB, speedcontrol 1-10 .l40shaftxl.125OD . LOCK, shaft pot .250-32 x .l25dia shaftPb1
.. 136127 . . 000 369 . 118 774 . 135 647 . . CASE, gun RH . SWITCH, lim 1OA 125/25OVAC DPST plgr . SPRING, cprsn .240 OD x .024 wire x 1.000 . NUT, stl 8-32 1 1 1 3 OM-1213 Page 19 Page 28
