OM-157 066V November 2000 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder R Auto Arc 255 And M-25 Gun For Warranty Claims And Technical Support, Contact: Milweld Inc., National Distributor P.O.
TABLE OF CONTENTS WARNING This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) The following terms are used interchangeably throughout this manual: MIG = GMAW OM-154 501V SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . .
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. 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 RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields.
SECTION 2 – INSTALLATION 2-1. Specifications Rated Welding Output Amperage Range DC Maximum OpenCircuit Voltage DC 40 – 250 42 200 A @ 28 Volts DC, 60% Duty Cycle 250 A @ 28 Volts DC, 40% Duty Cycle Amperes Input at Rated Load Output, 50 or 60 Hz, Single-Phase 200 V 230 V 460 V 575 V KVA KW 46 1.1* 40 1.3* 20 0.5* 16 0.4* 9.5 0.31* 8.3 0.18* Wire Type And Diameter Solid Steel / Stainless Steel Flux Cored/ Aluminum .023 – .045 in (0.6 – 1.2 mm) .030 – .035 in (0.8 – 0.
2-3. Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If 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 welding. Y Exceeding duty cycle can damage unit and void warranty.
2-5. Installing Work Clamp 1 2 Slide boot onto work cable. Route cable out front panel opening from inside. 4 3 Negative (–) Output Terminal Connect cable to terminal and cover connection with boot. 5 2 Work Cable Boot 4 5 Hardware Work Clamp Route cable through clamp handle and secure as shown. 1 Close door. Tools Needed: 3 1/2, 3/4 in ST-800 918-C 2-6. Installing Gas Supply 1 2 Cylinder Rack Chain Obtain gas cylinder and chain cylinder to rack.
2-7. Installing Welding Gun 1 2 3 1 2 Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly. Tighten nut. 4 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. 3 Ref. ST-800 921-C 2-8. Installing Wire Spool And Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. When a slight force is needed to turn spool, tension is set.
2-9. Setting Gun Polarity 1 1 Polarity Changeover Label Always read and follow manufacture’s recommended polarity. Tools Needed: 3/4, 11/16 in Ref. 190 821-A 2-10. Positioning Jumper Links 230 VOLTS Check input voltage available at site. 1 Jumper Links Access Door Open door. 460 VOLTS 200 VOLTS 2 2 3 Jumper Link Label Jumper Links Location Move jumper links to match input voltage, and label on unit. Close and secure access door.
2-11.
2-13. Threading Welding Wire 4 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. 7 Tools Needed: 1 2 3 6 5 4 in (102 mm) 6 in (150 mm) Open pressure assembly. Pull and hold wire; cut off end. . Use pressure indicator Tighten scale to set a desired drive roll pressure. Pressure Indicator Scale 1 2 3 4 Close and tighten pressure assembly, and let go of wire.
SECTION 3 – OPERATION 3-1. Front Panel Controls Controls For Standard Units 1 Wire Speed Control The scale around the control is percent, not wire feed speed. 1 2 2 Voltage Switch Use control and Voltage Range Selector (see Section 3-2) to set arc voltage. Step 6 of Low range and Step 1 of High range overlap. 3 4 Pilot Light Power Switch 3 4 Ref. ST-171 639-C / Ref.
3-2. Center Baffle Controls 1 Wire Mode Switch For better control of wire speed use the Low position when wire speed is between 90 and 670 ipm. Use the Full position when wire speed is between 150 ipm and 1030 ipm. 1 PRESS TO RESET CB1 2 2 Voltage Range Selector Place switch in desired position. DO NOT SWITCH UNDER LOAD WIRE MODE FULL LOW VOLTAGE RANGE HIGH LOW Ref.
3-3.
Ref.
SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance . Maintain more often Y Disconnect power before maintaining. during severe conditions. 3 Months Clean And Tighten Weld Terminals Repair Or Replace Cracked Cables And Cords Replace Damaged Or Unreadable Labels 6 Months Remove drive roll and carrier. Apply light coat of oil or grease to drive motor shaft. Blow Out Or Vacuum Inside 4-2. Circuit Breaker CB1 1 Circuit Breaker CB1 If CB1 opens, wire feeding stops.
4-3. Fuses F1 And F2 Y Turn Off unit, and disconnect input power. 1 Fuse F1 (See Parts List For Rating) F1 protects the 115 volts ac winding of transformer T1. If F1 opens, all weld output stops and pilot light PL1 goes out. 2 2 Fuse F2 (See Parts List For Rating) F2 protects the 24 volts ac winding of transformer T1. If F2 opens, all weld output stops. 1 Tools Needed: 3/8 in Ref. ST-800 928-B 4-4. Changing Drive Roll And Wire Inlet Guide 1 2 5 3 Securing Screw Inlet Wire Guide Loosen screw.
4-6. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun first. 3/8 in Head tube Remove nozzle, contact tip, adapter, and wire outlet guide. 3/8 in Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Insert new liner. Install and tighten wire outlet guide. Blow out gun casing. Cut liner off 3/4 in (20 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter, contact tip, and nozzle. Ref.
4-7. Replacing Switch And/Or Head Tube Y Disconnect gun first. 1 Remove handle locking nut. 3 2 4 Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure. Secure head tube in vice. 5 6 Loosen jam nut. Remove from vice and turn head tube out by hand.
4-8. Troubleshooting Welding Trouble No weld output; wire does not feed. Remedy Secure power cord plug in receptacle (see Section 2-12). Reset circuit breaker CB1 (see Section 4-2). Replace fuse F1 and/or F2 (see Section 4-3). Replace building line fuse or reset circuit breaker if open (see Section 2-12). Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section 2-7 and/or 4-7). Thermostat TP1 open (overheating).
SECTION 5 – ELECTRICAL DIAGRAM SB-173 544-E Figure 5-1.
Notes OM-157 066 Page 22
SECTION 6 – PARTS LIST . Hardware is common and not available unless listed. 11 10 8 9 Figure 6-2 – 2 Figure 6-4 – 7 1 3 6 5 12 13 14 15 16 Figure 6-6 - 20 17 18 Figure 6-5 – 19 ST-800 930-D Figure 6-1. Main Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Main Assembly . . . 1 . . . . . . . . . . . . . . . . . . . 146 168 . . . . . . . . . . . PLG7 . . . . . . . 083 526 . . . . . . . . . . . . . . . . . . . . . . . . . 009 418 . . . 2 . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Main Assembly . . . 8 . . . . . . . . . . . . . . . . . . . 146 165 . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 9 . . . . . . . . . . . . . . . . . . . 089 899 . . LATCH, slide flush mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 10 . . . . . . . . . . . . . . . . . . . 146 167 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . .
1 2 3 4 5 11 6 10 7 31 12 13 8 9 14 30 29 15 16 20 21 17 18 28 (Fig. 6–3) 19 22 27 23 26 25 24 . Hardware is common and not available unless listed. ST-800 931-D Figure 6-2.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 2) . . 1 . . . . . . . . . . . . 058 427 . . 2 . . . . . . . . . . . . 085 980 . . 3 . . . . . . . . . . . . 605 941 . . 4 . . . . . . . . . . . . 186 437 . . 5 . . . . . . . . . . . . 057 971 . . 6 . . . . . . . . . . . . 057 745 . . 7 . . . . . . . . . . . . 186 435 . . 8 . . . . . . . . . . . . 186 436 . . 9 . . . . . . . . . . . . 177 307 . . 10 . . . . . . . . . . . 174 812 . . . . . . . . . . .
See Table 6-1 Drive Roll & Wire Guide Kits. . Hardware is common and not available unless listed. 148 529-H Figure 6-3. Wire Drive And Gears Table 6-1. Drive Roll And Wire Guide Kits IMPORTANT: Base selection of drive rolls upon the following recommended usages: 1. V-Grooved rolls for hard wire. 2. U- Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4. V-Knurled rolls for hard shelled cored wires. 5.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-3. Wire Drive And Gears (Fig 6-2 Item 28) . . . 1 . . . . . . . . . . . . . . . . . . . 602 009 . . . 2 . . . . . . . . . . . . . . . . . . . 172 075 . . . 3 . . . . . . . . . . . . . . . . . . . 166 072 . . . 4 . . . . . . . . . . . . . . . . . . . 010 224 . . . 5 . . . . . . . . . . . . . . . . . . . 182 788 . . . 6 . . . . . . . . . . . . . . . . . . . 085 242 . . . 7 . . . . . . . . . . . . . . . . . . . 196 896 . . . 8 . . . . . . . . . .
. Hardware is common and 4 not available unless listed. 3 2 1 5 6 18 17 16 15 7 14 13 12 11 10 9 8 ST-802 288 Figure 6-4. Panel, Rear w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-4. Panel, Rear w/Components (Fig 6-1 Item 7) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ................... ................... ................... ................... ................... ................... ...
. Hardware is common and not available unless listed. 7 9 8 6 5 4 3 10 2 1 11 15 14 ST-802 287 13 12 Figure 6-5. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-5. Panel, Front w/Components (Fig 6-1 Item 19) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1 . . . . . . . . . . . . 148 956 . . 2 . . . . . . . . . . . . 097 924 . . 3 . . . . . . . . . . . . 171 639 . . 4 . . . . . . . . . . . . 155 418 . . 5 . . . . . R2 . . . 035 897 . . 6 . . . . . . . . . .
16 12 11 9 14 13 15 12 11 10 9 8 17 7 6 5 4 3 2 1 Ref. 800 792-B Figure 6-6.
Item No. Part No. Description Quantity Figure 6-6. Exploded View Of Gun (Fig 1 Item 20) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 1 1 1 1 2 2 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 15 16 17 . . . . . 200 258 . . . ♦169 724 . . . ♦169 725 . . . ♦169 726 . . . ♦169 727 . . . ♦130 792 . . . ♦130 794 . . . ♦130 796 . . . ♦130 798 . . . . . 169 728 . . . . . 169 729 . . . . . 170 467 . . . . . 170 468 . . . . . 169 730 . . . . . 169 731 . . .
Notes
Notes
Warranty Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY – Subject to the terms and conditions below, warrants to its original retail purchaser that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped from factory.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Resources Available Always provide Model Name and Serial/Style Number.