Millermatic. Processes. Description. December Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding

Transcription

1 OM-308 December 997 Processes 44M Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic 50 Visit our website at

2

3 The following terms are used interchangeably throughout this manual: MIG = GMAW TABLE OF CONTENTS SECTION SAFETY PRECAUTIONS - READ BEFORE USING Symbol Usage Arc Welding Hazards Additional Symbols for Installation, Operation, and Maintenance Principal Safety Standards EMF Information SECTION INSTALLATION Specifications Duty Cycle And Overheating Volt-Ampere Curves Installing Work Clamp Installing Welding Gun Setting Gun Polarity For Wire Type Installing Gas Supply Installing Wire Spool And Adjusting Hub Tension Positioning Jumper Links Electrical Service Guide Selecting A Location And Connecting Input Power Threading Welding Wire SECTION 3 OPERATION Controls Installing Receptacle Module For Use With A Spool Gun (Optional) SECTION 4 MAINTENANCE AND TROUBLESHOOTING Routine Maintenance Circuit Breaker CB Unit Overload Replacing Gun Contact Tip Installing Drive Roll And Wire Inlet Guide Aligning Drive Rolls And Wire Guide Unicable Repair Cleaning Or Replacing Gun Liner Replacing Switch And/Or Head Tube Troubleshooting SECTION 5 ELECTRICAL DIAGRAM SECTION 6 PARTS LIST OPTIONS AND ACCESSORIES WARRANTY

4

5 SECTION SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 -. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. 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. -. Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section -4. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. 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. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 9 CFR (see Safety Standards). Properly install and ground this equipment according to its Owner s Manual and national, state, and local codes. Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first double-check connections. Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable do not use work clamp or work cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the manufacturer s instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-308 Page

6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. 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. Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49. and Z87. listed in Safety Standards). Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection. HOT PARTS can cause severe burns. Do not touch hot parts bare handed. Allow cooling period before working on gun or torch. WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (0.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4. (see Safety Standards). Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. FLYING METAL can injure eyes. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. MAGNETIC FIELDS can affect pacemakers. Pacemaker wearers keep away. Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. 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. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P- listed in Safety Standards. OM-308 Page

7 -3. Additional Symbols for Installation, Operation, and Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. Do not overload building wiring be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cause injury. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit. H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. MOVING PARTS can cause injury. Keep away from moving parts. Keep away from pinch points such as drive rolls. WELDING WIRE can cause injury. 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. ARC WELDING can cause interference. Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 00 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. -4. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49., from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 336 Safety and Health Standards, OSHA 9 CFR 90, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4., from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 336 National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 069. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-, from Compressed Gas Association, 35 Jefferson Davis Highway, Suite 50, Arlington, VA 0. Code for Safety in Welding and Cutting, CSA Standard W7., from Canadian Standards Association, Standards Sales, 78 Rexdale Boulevard, Rexdale, Ontario, Canada M9W R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87., from American National Standards Institute, 430 Broadway, New York, NY 008. Cutting And Welding Processes, NFPA Standard 5B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 069. OM-308 Page 3

8 -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. However, after examining more than 500 studies spanning 7 years of research, a special blue ribbon committee of the National Research Council concluded that: The body of evidence, in the committee s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures:. Keep cables close together by twisting or taping them.. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended. OM-308 Page 4

9 SECTION INSTALLATION -. Specifications 50 A at 8 VDC, 40% Duty Cycle Rated Output 00 A at 8 VDC, 60% Duty Cycle Max. Open- Amps Input at Rated Output, 50 or 60 Hz, Single-Phase Circuit Voltage 00 V 0 V 30 V 380 V 45 V 460 V 575 V KVA KW * 45.* 44 * 6.3* 4.* * 8 0.8* * Wire Type and Diameter Wire Feed Speed Dimensions Net Weight Solid Steel Stainless Steel Flux Cored IPM H: 37 in (940 mm) (..7 m/min) W: 9 in (483 mm) in in in D: 30-/4 in (768 mm) (0.6. mm) ( mm) (0.8. mm) * While idling 5 lb (0 kg) * -. Duty Cycle And Overheating Duty Cycle is percentage of 0 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. Exceeding duty cycle can damage unit and void warranty. 60% Duty Cycle At 00 Amperes 40% Duty Cycle At 50 Amperes 6 Minutes Welding 4 Minutes Resting 4 Minutes Welding 6 Minutes Resting Overheating 0 A or V Minutes 5 OR Reduce Duty Cycle duty 4/95 SB-50 5 OM-308 Page 5

10 -3. Volt-Ampere Curves Normal Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. Overload Volt-Ampere Curves When unit is used beyond capacity, circuitry senses the overload and shuts down unit output. Release trigger and lower weld voltage setting before trying to weld. This shut down circuitry protects internal circuits and parts from overload damage DC VOLTS 30 0 * * DC AMPERES *Approximate shutdown voltage/amperage points shown for reference only. ssb. 0/9 SB / S Installing Work Clamp 5 4 Work Cable Boot Slide boot onto work cable. Route cable out front panel opening from inside. 3 Negative ( ) Output Terminal Connect cable to terminal and cover connection with boot. 4 Hardware 5 Work Clamp Route cable through clamp handle and secure as shown. Close door. 3 Tools Needed: /, 3/4 in ST-50 8-E OM-308 Page 6

11 -5. Installing Welding Gun Drive Assembly Gun Securing Knob 3 Gun End 4 Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. 3 Ref. ST D -6. Setting Gun Polarity For Wire Type Always read and follow wire manufacturer s recommended polarity, and see label inside unit by wire drive assembly. Tools Needed: 3/4 in -7. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Cap Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 3 Cylinder 4 Regulator/Flowmeter 4 Install so face is vertical. Argon Gas 5 Regulator/Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection 5 7 OR Connect customer supplied gas hose between regulator/flowmeter gas hose connection, and fitting on rear of welding power source. 7 Flow Adjust 8 9 CO Gas 3 Typical flow rate is 0 cfh (cubic feet per hour). Check wire manufacturer s recommended flow rate. 8 CO Adapter (Customer Supplied) 9 O-Ring (Customer Supplied) 6 Install adapter with O-ring between regulator/flowmeter and CO cylinder. Tools Needed: -/8, 5/8 in Ref. ST B / ST OM-308 Page 7

12 -8. Installing Wire Spool And Adjusting Hub Tension Use compression spring with 8 in (00 mm) spools. When a slight force is needed to turn spool, tension is set. Tools Needed: 5/6 in ST B -9. Positioning Jumper Links Check input voltage available at site. Jumper Links Access Door 3 00 VOLTS 30 VOLTS 30 VOLTS 460 VOLTS 0 VOLTS 380 VOLTS Open door. Jumper Link Label Check label only one is on unit. 3 Input Voltage Jumper Links Move jumper links to match input voltage. 460 VOLTS 575 VOLTS 45 VOLTS Close and secure access door. S C S A S A Tools Needed: 3/8 in Ref. ST C OM-308 Page 8

13 -0. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) 93 (8) 75 (3) 8 (5) 37 (4) 63 (50) 39 (00) 33 (95) Min Grounding Conductor Size In AWG/Kcmil Reference: 996 National Electrical Code (NEC). S-009J -. Selecting A Location And Connecting Input Power 8 in (457 mm) for airflow Have only qualified persons make this installation. Rating Label Supply correct input power. Special installation may be required where gasoline or volatile liquids are present see NEC Article 5 or CEC Section 0. GND/PE GND/PE Connect First L L Size and ratings must comply with applicable codes. Install conductors in conduit or equivalent into a deenergized line disconnect device. ST-80 7 OM-308 Page 9

14 -. Threading Welding Wire 4 Wire Spool 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: Hold wire tightly to keep it from unraveling. 6 in (50 mm) 4 in (0 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, and let go of wire. Remove gun nozzle and contact tip. Turn On. WOOD Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire. Close and latch door. Ref. ST-48 6-C / ST-59 8-B / ST / S-067-A OM-308 Page 0

15 SECTION 3 OPERATION 3-. Controls 3 Wire Speed Control The scale around the control is percent, not wire feed speed. Voltage Switch The scale around the control is actual voltage. 3 Low Range/Full Range Switch Use Low Range when wire speed is between 50 and 350 ipm. 4 Pilot Light 5 Power Switch 4 5 Ref. ST A / Ref. ST A 3-. Installing Receptacle Module For Use With A Spool Gun (Optional) Remove existing options panel. Module Plug PLG9 3 Plug PLG7 3 Connect PLG9 to PLG7. Slide module into upper front panel where options panel was removed. Secure with screws. See Options and Accessories page at end of manual, or contact your Factory Authorized Service Agent for details. Tools Needed: ST OM-308 Page

16 SECTION 4 MAINTENANCE AND TROUBLESHOOTING 4-. Routine Maintenance Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. during heavy service clean monthly. OR Remove drive roll and carrier. Apply light coat of oil or grease to drive motor shaft. 4-. Circuit Breaker CB Circuit Breaker CB If CB opens, wire feeding stops. Welding Gun Check gun liner for blockage or kinks. 3 Wire Drive Assembly Check for jammed wire, binding drive gear or misaligned drive rolls. Allow cooling period and reset breaker. Close door. 3 Ref. ST-48 6-C 4-3. Unit Overload If unit is used beyond capacity (excessive wire feed, shorted output, etc.), wire feeds but is not energized. Release gun trigger to reset this condition. OM-308 Page

17 4-4. Replacing Gun Contact Tip Turn Off power. Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: ST B 4-5. Changing Drive Roll And Wire Inlet Guide 3 5 Securing Screw Tools Needed: 5/64 in 7/6 in 4 Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 Anti-Wear Guide Install guide as shown. 4 Drive Roll Install correct drive roll for wire size and type. 5 Drive Roll Securing Nut Turn nut one click to secure drive roll. ST-50 7-C 4-6. Aligning Drive Rolls And Wire Guide Turn Off power. 3 Correct 4 Incorrect View is from top of drive rolls looking down with pressure assembly open. Drive Roll Securing Nut Drive Roll 3 Wire Guide 4 Welding Wire 5 5 Drive Gear Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide. Close pressure roll assembly. Close door. Tools Needed: Ref. ST A 4-7. Unicable Repair To repair or replace unicable, order Unicable Clamp Kit, Part Number OM-308 Page 3

18 4-8. Cleaning Or Replacing Gun Liner Disconnect gun first. Tools Needed: 3/8 in Head tube Remove nozzle, contact tip, adapter, and wire outlet guide. 3/8 in Wire Outlet Guide Remove liner. Lay gun cable out straight before installing new liner. Blow out gun casing. To Reassemble Gun: Insert new liner. Install and tighten wire outlet guide. Cut liner off 3/4 in (0 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter, contact tip, and nozzle. Ref. ST A OM-308 Page 4

19 4-9. Replacing Switch And/Or Head Tube Disconnect gun first. 3 Slide handle. Remove handle locking nut. 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. 4 Secure head tube in vice. 5 Remove shock washers from front and rear of head tube. 6 Loosen jam nut. Remove from vice and turn head tube out by hand. Do not disturb cable connection between cable connector and connector nut. 7 Install both existing shock washers to new head tube and hand-tighten head tube into connector cable. 8 Place head tube in vice and tighten to within /8 in (3. mm) spacing between connector cable and body. 9 Remove from vice. Reposition handle and install switch housing. Secure with handle locking nut. Tools Needed: 3/4 in Ref. ST A OM-308 Page 5

20 4-0. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section -). Replace building line fuse or reset circuit breaker if open (see Section -). Reset circuit breaker CB (see Section 4-). Secure gun trigger connections (see Section -5). Check and replace Power switch if necessary. Have Factory Authorized Service Agent check all board connections and main control board. No weld output; wire feeds. Thermostat TP open (overheating). Allow fan to run; the thermostat will close when the unit has cooled (see Section -). Connect work clamp to get good metal to metal contact. Replace contact tip (see Section 4-4). An overload condition occurred. Release gun trigger (see Section 4-3). Have Factory Authorized Service Agent check main control board and main rectifier. Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section -). Check input voltage jumper links and correct position if necessary (see Section -9). Have Factory Authorized Service Agent check main control board. Fan motor does not run. NOTE: Fan only runs when cooling is necessary. Have Factory Authorized Service Agent check fan-on-demand circuit. Low, high, or erratic wire speed. Readjust front panel settings (see Section 3-). Place Low Range/Full Range switch in correct position (see Section 3-). Change to correct size drive rolls (see Section 4-5). Readjust drive roll pressure (see Section -). Replace inlet guide, contact tip, and/or liner if necessary (see Sections 4-4, and 4-8). Check position of input jumper links (see Section -9). Have Factory Authorized Service Agent check main control board. No wire feed. Reset circuit breaker CB (see Section 4-). Turn Wire Speed control to higher setting (see Section 3-). Clear obstruction in gun contact tip or liner (see Sections 4-4 and 4-8). Readjust drive roll pressure (see Section -). Change to correct size drive rolls (see Section 4-5). Rethread welding wire (see Section -). Check gun trigger and leads. Repair or replace gun if necessary. Have Factory Authorized Service Agent check main control board. Poor weld bead, or welding wire is noodle welding. Check polarity setting for type of welding wire being used (see Section -6). OM-308 Page 6

21 SECTION 5 ELECTRICAL DIAGRAM Figure 5-. Circuit Diagram SC A OM-308 Page 7

22 SECTION 6 PARTS LIST Hardware is common and not available unless listed. 5 Fig Fig Fig Fig ST OM 308 Page 8 Figure 6-. Main Assembly

23 Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-. Main Assembly COUPLER, rod threaded.3-8 x PANEL, center enclosure PLG HOUSING RECEPTACLE & SOCKETS Fig BAFFLE, center w/components T TRANSFORMER, pwr main (00/30/460) (consisting of) T TRANSFORMER, pwr main (30/460/575) (consisting of) T TRANSFORMER, pwr main (0/380/45) (consisting of) TP THERMOSTAT BAFFLE, air transformer WASHER, flat stl SAE WHEEL Z STABILIZER, (60Hz) Z STABILIZER, (50Hz) Fig PANEL, rear w/components PANEL, side LH LATCH, slide flush mtg hole.000 wide x.500 lg PANEL, side LABEL, weld parameters LABEL, warning general precautionary WRAPPER BLANK, snap-in nyl.87mtg hole PLG CORD SET, pwr 50V 8-0ga 3/c 600V ft (00/30V) RECEPTACLE, str P3W 50A 50V (00/30V only) CORD SET, pwr 8-0ga 3/c 600V ft BASE AXLE, running gear (consisting of) RING, retaining ext.750 shaft x.085grv depth SR RECTIFIER, SCR main (consisting of) CLAMP, spring thyristor rectifier HEAT SINK, rectifier C3, CAPACITOR, rectifier THYRISTOR, SCR 35A 300V hockey puck TP THERMOSTAT, NC HEAT SINK, rectifier FOOT, mtg rectifier TP THERMOSTAT, NO CLAMP, thyristor rectifier WASHER, lock stl split CASTER, plstc swvl 4 in dia NUT, stl hex jam Fig PANEL, front w/components GUN, ft wire (Fig 6-6) REGULATOR/FLOWMETER, 0-50 CFH Argon/CO HOSE, gas CLAMP, ground 350A CABLE, weld cop strd No. 3 (order by ft) ft +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-308 Page 9

24 Hardware is common and not available unless listed Fig ST C Figure 6-. Baffle, Center w/components OM 308 Page 0

25 Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-. Baffle, Center w/components (Fig 6- Item 4) RING, retaining spool NUT, stl hex full WASHER, flat stl.640 ID x.000 OD x 4ga thk SPRING, cprsn.845 OD x.09 wire x WASHER, flat stl keyed.500dia x.5thk WASHER, fbr.656 ID x.500 OD x.5thk WASHER, brake stl SPRING, cprsn.430 OD x.090 wire x HUB, spool REEL, support BAFFLE, center CAPACITOR KIT,(consisting of) STRIP, mtg center capacitor STRIP, mtg capacitors C CAPACITOR, elctlt 5000uf 45VDC GROMMET, scr No. 8/0 panel hole.3sq.500 high INSULATOR CR RELAY, encl 4VAC DPDT VR VARISTOR, 75 joule 350VDC TE TERMINAL ASSEMBLY, pri ph triple voltage (consisting of) WASHER, flat brs.8 ID x.460 OD x.03thk STUD, pri bd brs 0-3 x TERMINAL BOARD, pri NUT, brs hex LINK, jumper term bd pri TUBING, stl.75 ID x.048 wall x.000 lg PC CIRCUIT CARD, control main PLG HOUSING PLUG & SOCKETS PLG HOUSING RECEPTACLE & SOCKETS PLG HOUSING RECEPTACLE & SOCKETS PLG HOUSING PLUG & SOCKETS R RESISTOR, WW fxd 300W 5 ohm T TERMINAL, frict male.50 x.03 3 pair C7, CAPACITOR POS TERMINAL, pwr output red NEG TERMINAL, pwr output black COVER, cable CB CIRCUIT BREAKER, man reset P 4A 50VAC STAND-OFF SUPPORT, PC card DOOR, access chgov LABEL, danger high voltage Fig WIRE DRIVE & GEARS When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-308 Page

26 Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-3. Panel, Front w/components (Fig 6- Item 4) CONTROL PANEL, (consisting of) R RESISTOR, MF.5W.5K ohm S SWITCH, rocker SPDT 4A 50VAC KNOB, pointer.65dia x.50 ID PLATE, indicator upper (order by model and serial number) PANEL, front control R, POTENTIOMETER HANDLE, running gear C LEAD ASSEMBLY, elect C LEAD ASSEMBLY, elect RC RECEPTACLE w/sockets S SWITCH, tgl DPST 40A 600VAC PANEL, front PLATE, indicator lower (order by model and serial number) PL LIGHT, ind white lens 8V BUSHING, snap-in nyl.937 ID x.5mtg hole COVER, opening module Hardware is common and not available unless listed ST Figure 6-3. Panel, Front w/components To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM 308 Page

27 Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-4. Wire Drive And Gears (Fig 6- Item 35) SCREW,.50-0 x.5 soc hd gr CARRIER, drive roll w/components SPACER, gear PIN, spring CS.87 x HOUSING, adapter gun/feeder FASTENER, pinned WASHER, cupped stl.38 ID x.8 OD x.5 lip SPRING, cprsn.770 OD x.05 wire x KNOB, adj tension LEVER, mtg pressure gear PIN, hinge PIN, cotter hair.054 x COVER, right angle motor PM MOTOR, gear 4VDC RPM 0: ratio FITTING, hose brs barbed M 3/6tbg SCREW, x.5hexhd STOP, cover WASHER, flat stl SAE KNOB, plstc T.000 lg x.3-8 x.000 bar CARRIER, drive roll w/components SCREW, M 4.7 x SCREW, M 6.0 x 0 soc hd BUSHING, motor mtg GUIDE, anti-wear Hardware is common and not available unless listed See Table 6- For Drive Roll & Wire Guide Kits ST C Figure 6-4. Wire Drive And Gears *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-308 Page 3

28 Note Table 6-. Drive Roll And Wire Guide Kits Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire. 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 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved). Wire Diameter Fraction Decimal Metric Kit No. Drive Roll Part No. Type Inlet Wire Guide.03/.05 in..030 in..03/.05 in..030 in. 0.6 mm 0.8 mm V-Grooved V-Grooved in..045 in..035 in..045 in. 0.9 mm. mm V-Grooved V-Grooved Ref. S-006-B/7-9 Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-5. Panel, Rear w/components (Fig 6- Item 0) HOSE, SAE.87 ID x.40 OD (order by ft) ft CLAMP, hose clp dia slfttng GS VALVE, 4VAC way custom port /8 orf PANEL, rear BRACKET, support tank CHAIN, weldless /0 x lg NUT, nyl hex jam.750npst CONNECTOR, clamp cable.690/ BUSHING, snap-in nyl.65 ID x.875mtg hole WINDTUNNEL, 9 in FM MOTOR, fan 30V 550RPM.3dia shaft BLADE, fan 9 in 5wg 34deg.309 bore CCW NUT, speed push-on-type.3 stud.65 OD x.456 ID Hardware is common and not available unless listed Figure 6-5. Panel, Rear w/components ST C To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM 308 Page 4

29 Item No. Part No. Description Quantity Figure 6-6. M-5 Gun (Fig 6- Item 5) NOZZLE, slip type.500 orf.5 recess NOZZLE, slip type.65 orf.5 recess NOZZLE, slip type.65 orf flush NOZZLE, slip type.65 orf.5 stickout NOZZLE, spot flat NOZZLE, spot inside corner NOZZLE, spot outside corner TIP, contact scr.03 wire x TIP, contact scr.030 wire x TIP, contact scr.035 wire x TIP, contact scr.045 wire x ADAPTER, contact tip ADAPTER, nozzle RING, retaining O-RING WASHER, shock TUBE, head NUT, locking handle NUT, jam CONNECTOR, cable NUT, connector M5 UNICABLE CLAMP KIT, (consisting of) CLIP, compression TUBE, support CLAMP, inner CLAMP, jacket CONNECTOR, switch lead Hardware is common and not available unless listed * *Includes Item 8 0 ST Figure 6-6. M-5 Gun OM-308 Page 5

30 Item No. Part No. Description Quantity Figure 6-6. M-5 Gun (Fig 6- Item 5) (Continued) HANDLE STRAIN RELIEF, cable CABLE, trigger CONNECTOR, feeder (consisting of) O-RING,.500 ID x.03cs rbr KIT, liner monocoil.03/.05 wire x 5ft (consisting of) KIT, liner monocoil.030/.035 wire x 5ft (consisting of) KIT, liner monocoil.035/.045 wire x 5ft (consisting of) O-RING,.87 ID x.03cs rbr GUIDE, outlet SWITCH, trigger OPTIONAL To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM 308 Page 6