Miller Electric GL-25 User manual

September

1977

FORM:

OM-1515

liETU~~~

Copy

Effective

With

Style

No.

HH-1

MODEL

GL-25

GL-40

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

OWNER.S

MANUAL

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

ADDITIONAL

COPY

PRICE

CENTS

NWSA

CODE

NO.

4579

~&.a~

L~P

LLP

I

LIMITED

WARRANTY

EFFECTIVE:

NOVEMBER

1976

This

warranty

supersedes

all

MILLER

warranties

and

clusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTYMiller

Electric

Mfg.

Co., Apple-

Arc

welders,

power

sources,

and

components

. . .

year

ton,

Wisconsin

warrants

Customer

that

all

new

and

unused

Original

main

power

rectifiers

years

Equipment

furnished

Miller

free

from

defect

workman-

(Labor



year

only)

ship

and

material

the

time

and

place

delivery

Miller.

All

welding

guns

and

feeder/guns

(lays

warranty

made

Miller

with

respect

engines,

trade

accessories

other

items

manufactured

others.

Such

engines,

All

other

Millermatic

Feeders

year

trade

accessories

and

other

items

are

sold

subject

the

warran-

provided

that

the

user

notifies

Miller

writing

within

thirty

ties

their

respective

manufacturers,

any.

the

present

time,

(30)

days

the

date

such

failure.

the

manufacturers

warranty

the

Mag-Diesel

engine

DEL-

200

limited

six

months

and

all

other

engines

one

year.

Replacement

repair

parts

exclusive

labor

days

MILLER

warranty

does

not

apply

components

having

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

normal

useful

life

less

than

one

(I)

year,

such

spot

welder

AND

ANY

IMPLIED

WARRANTY,

GUARANTY

REP-

tips,

relay

and

contactor

points,

MILLERMATIC

parts

that

RESENTATION AS

PERFORMANCE,

AND

ANY

come

contact

with

the

welding

wire

including

nozzles

and

REMEDY

FOR

BREACH

CONTRACT

WHICH,

BUT

nozzle

insulators

where

failure

does

not

result

from

defect

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICA

workmanship

material.

TION,

OPERATION OF

LAW,

CUSTOM

TRADE

the

case

Millers

breach

warranty

any

other

duty

COURSE

DEALING,

INCLUDING

ANY

IMPLIED

with

respect

the

quality

any

goods,

the

exclusive

remedies

WARRANTY

MERCHANTABILITY

FITNESS

therefor

shall

be,

Millers

optIon,

(1)

repair

(2)

replace-

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

ment

or,

where

authorized

writing

Miller

appropriate

AND

ALL

EQUIPMENT

FURNISHED

MILLER

cases,

(3)

the

reasonable

cost

repair

replacement

EXCLUDED

AND

DISCLAIMED

MILLER.

authorized

Miller

service

station

(4)

payment

credit

for

EXCEPT

EXPRESSLY

PROVIDED

MILLER

the

purchase

price

(less

reasonable

depreciation

based

upon

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

actual

use)

upon

return

of the

goods

Customers

risk

and

CX~

ULTIMATE

PURCHASE

COMMERCIAL/INDUS

pense.

Upon

receipt

notice

apparent

defect

failure,

TRIAL

USERS

AND

FOR

OPERATION

PERSONS

Miller

shall

instruct

the

claimant

the

warranty

claim

proce-

TRAINED

AND

EXPERIENCED

THE

USE

AND

dures

followed.

MAINTENANCE

WELDING

EQUIPMENT

AND

NOT

matter

general

policy

only,

Miller

may

honor

origi-

FOR

CONSUMERS OR

CONSUMER

USE.

MILLER

nal

users

warranty

claims

warranted

Equipment

the

event

WARRANTIES

NOT

EXTEND

TO,

AND

RE-

failure

resulting

from

defect

within

the

following

periods

SELLER

AUTHORIZED

EXTEND

MILLERS

WAR

(

from

the

date

delivery

Equipment

the

original

user:

RANTIES

TO,

ANY

CONSUMER.

...~i,

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

flLE

COPY

RETUG~N

~LDE~

Item

Part

No.

Listed

No.

Parts

List

052084

052085

SURE

PROVIDE

Replaced

With

Part

No.

Description

Quantity

081

580

LINER,

monocoil

0.230

.030

1/8

wire

lift

081

581

LINER,

moriocoil

0.230

.030

1/8

wire

MODEL

AND

STYLE

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-1515

Page

1

~I~I

r~~

SECTION

INTRODUCTION

Rating:

60%

Duty

Cycle

Wire

Diameter

Cooling

Method

Cable

Length

Net

Weight

Ship

Weight

250

Amperes

1/16

and

5/64

icr

7lbs.4oz.

(3.29

kilos)

9lbs.4oz.

(4.20

kilos)

15

9lbs.Boz.

(4.31

kilos)

lbs.8oz.

)5.22

kilos)

400

Amperes

i/16,5/64,

and

3/32

Air

lbs.

(4.08

kilos)

lbs.

)5.00

kilos)

15

lbs.

(4.99

kilos)

lbs.

)5.90

kilos)

Figure

1-1.

Specifications

1-1.

GENERAL

This

manual

has

been

prepared

especially

for

use

familiar

izing

personnel

with

the

design,

installation,

operation,

main

tenance,

and

troubleshooting

this

equipment,

All

informa

__________________

tion

presented

herein

should

given

careful

consideration

assure

optimum

performance

this

equipment.

1-2.

RECEIVING-HANDLING

Prior

installing

this

equipment,

clean

all

packing

material

from

around

the

unit

and

carefully

inspect

for

any

damage

that

may

have occurred

during

shipment.

Any

claims

for

loss

damage

that

may

have

occurred

transit

must

filed

the

purchaser

with

the

carrier.

copy

the

bill

lading

and

freight

bill

will

furnished

the

carrier

request

occasion

file

claim

arises,

When

requesting

information

concerning

this

equipment,

essential

that

Model

Description

and/or

Stock

Number

and

Serial

(or

Style)

Numbers

the

equipment

supplied.

1-3.

DESCRIPTION

___________

This

gun

designed

specifically

for

use

with

the

self-shielding

Flux-Cored

Arc

)FCAW)

Welding

process

using

self-shielding

flux-cored

electrode.

The

gun

may

used

for either

straight

reverse

polarity

applications.

All

necessary

components

for

the

specific

wire

size

ordered

are

shipped

with

the

gun.

The

Contact

tube

the

only

component

that

needs

changed

when

wire

size

change

desired.

_____________

SECTION

INSTALLATION

2-1.

INSTALLATION

MONOCOIL

LINER

Lay

gun

cable

out

straight.

Insert

monocoil

liner

fully

into

casing;

push

until

seats

firmly

against

wire

straightener

(in

head

tube

behind

contact

tube;

see

Parts

List

for

view).

Tighten

set

screw

head

tube

(via

clearance

hole

top

handle)

and

cable

Connector.

not

overtighten.

the

monocoil

liner

protrudes

from

the

cable

connector

)feeder

end),

cut

the

liner

off

flush

with

the

end

the

cable

connector.

2-2.

INSTALLATION

GUN

TRIGGER

SWITCH

PLUG



Make

connections

from

the

gun

trigger

switch

cord

the

plug

for

the

control/feeder

follows:

plug:

Attach

the

two

wires

the

two

terminals

the

plug;

tighten

screws;

slide

insulator

onto

plug.

LN-7

and

LN-8:

Slide

the

cable

clamp

(strain

relief)

onto

the

cord;

solder

the

two

wires

pins

and

Con

the

five-pin

plug;

secure

clamp

plug

body;

tighten

screws.

1-4.

SAFETY

The

following

definitions

apply

CAUTION,

IMPORTANT.

and

NOTE

blocks

found

throughout

this

manual:

1L~Il.J~IIuIIJ

Under

this

heading,

installation,

ope

rating,

and

main-

tenance

procedures

practices

will

found

that

not

carefully

followed

may

create

hazard

per

sonnel.

r~TA~1

Under

this

heading,

installation,

operating,

and

main

tenance

procedures

practices

will

found

that

not

carefully

followed

may

result

damage

equip

ment.

NOTE

Under

this

heading,

explanatory

statements

will

found

that

need

special

emphasis

nhtain

the

most

efficient

operation

the

equipment

LN-22:

Slide

the

cable

clamp

(strain

relief)

Onto

the

cord;

solder

the

two

wires

pins

and

the

three-pin

plug;

secure

clamp

plug

body;

tighten

screws.

2900:

Slide

the

cable

clamp

(strain

relief)

onto

the

cord;

solder the

two

wires

pins

and

the

four-pin

plug;

secure

clamp

plug

body;

tighten

screws.

When

the

connections

have

been

properly

made,

the

plug

ready

be attached

the

control/feeder

gun

switch

receptacle.

Prior

installing

the

gun,

ensure

that

the

control/

feeder

and

welding

power

source

are

both

completely

disconnected

from

their

respective

input

electrical

power

supplies.

2-3.

GUN

CONTROL/FEEDER

CONNECTIONS

Slide

one

end

the

interconnecting

power

cable

onto

the

threads

end

cable

connector,

where

applicable.

OM-1515

Page

Rotate

outlet

guide

onto

cable

connector;

tighten

outlet

guide.

Loosen

the

outlet

guide

securing

screw

the

drive

assembly

the

control/feeder.

Insert

the

outlet

guide

from

the

gun

cable

all

the

way

into

the

outlet

guide

hole

the

drive

assembly

the

control/feeder.

Tighten

the

outlet

guide

securing

screw.

Connect

the

plug

installed

Section

2-2

the

gun

switch

receptacle

the

control/feeder.

Connect

the

remaining

end

the

interconnecting

power

cable

the

weld

cable

terminal

the

control/feeder,

where

applicable.

2-4.

CHANGING

WIRE

SIZE

The

contact

tube

the

gun

the

only

component

the

gun

and

gun

cable

assembly

that

needs

changed

accommodate

different

wire

size.

The

contact

tube

threaded.

remove,

rotate

counterclockwise

direction;

install,

rotate

clockwise

direction.

2-5.

NOZZLE

nozzle

(1-3/4)

recommended

for

normal

applications.

longer

stick

out

the

electrode

desired,

longer

nozzle

(2-3/8)

available

but

must

ordered

(see

Parts

List).

Should

very

work

done

where

the

nozzle

not

desired,

thread

protector

available

for

use

when

the

nozzle

removed

(see

Parts

List).

SECTION

MAINTENANCE

Lay

cable

out

straight.

Insert

monocoil

liner

fully

into

casing;

push

until

seats

firmly

against

wire

straightener

(in

head

tube

behind

contact

tube;

see

Parts

List

for

view).

Tighten

set

screw

head

tube

and

cable

connector.

not

overtighten.

new

monocoil

liner

has

been

installed,

cut

the

liner

off

flush

with

the

feeder

end

the

cable

connector.

Reinstall

the

interconnecting

power

cable,

where

applicable.

Reinstall

the

outlet

guide.

3-2.

INSPECTION

AND

UPKEEP

Usage

and

conditions

will

determine

the

frequency

and

type

maintenance

required.

Inspect

gun

for

broken

areas,

cracks,

and

loose

parts;

tighten,

repair,

and

replace

required.

Carefully

remove

any

weld

spatter

foreign

matter

which

may

accumulate

around

the

nozzle

orifice.

Repair

replace

cables

required;

give

particular

attention

frayed

and

cracked

insulation

and

areas

where

the

cables

enter

equipment.

Remove

grease

and

grime

from

components;

moisture

from

electrical

parts

and

cables.

L!1

Ensure

that

the

welding

power

source

completely

shut

down

and

that

power

removed

from

the

control/feeder

prior

performing

any

maintenance

procedures.

3-1.

CLEANING

MONOCOIL

LINER

Periodically,

depending

usage

and

conditions,

will

necessary

clean

the

monocoil

liner

and

casing

remove

any

metal

chips

and

dirt

that

may

have

accumulated.

clean,

proceed

follov~s:

Remove

monocoil

liner

follows;

Remove

outlet

guide

from

cable

connector.

Remove

interconnecting

power

cable

from

cable

con

nector,

where

applicable.

Remove

set

screw

from

cable

connector

and

from

head

tube

(via

clearance

hole

sop

handle).

Lay

cable

out

straight,

and

pull

monocoil

liner

out

from

feeder

end.

Blow

monocoil

liner

out

with

clean,

dry,

compressed

air.

Blow

casing

out

same

manner.

Reinstall

monocoil

liner

follows;

Page

September

1977

FORM:

OM-1515

Effective

With

Style

No.

HH-1

MODEL

GL-25

GL-40

MODEL/STOCK

NO.

SERIAL/STYLE

NO.

DATE

PURCHASED

PARTS

LIST

MILLER

ELECTRIC

MFG.

CO.

APPLETON,

WISCONSIN,

USA

54911

NWSA

CODE

NO.

4579

Figure



Complete

Assembly

TC-052

230

2 3

OM-1515

Page

Quantity

Item

Factory

Model

No.

Part

No.

Description

GL-25

GL-40

Figure

Complete

Assembly

601

957

SCREW,

cap

steel

hex

1/4-20

1-1/2

052

066

HANDLE,

gun

left

hand

076

762

PIN,

spring

compression

000

369

SWITCH,

limit

amp

125/250

volts

SPDT

052064

TRJGGER,gun

052

884

SCREW,

set

steel

socket

10-32

1/4

052

072

TUBE,

head

inch)

052

074

INSERT,

straightener

wire

052 098

SCREW,

set

steel

hollow

3/8-16

3/16

052

059

PROTECTOR,

thread

052

078

NOZZLE,

screw

1-3/4

052

075

NOZZLE,

screw

2-3/8

009709

TUBE,contact

1/l6wireor

052

055

TUBE,

contact

5/64

wire

008

926

TUBE,

contact

3/32

wire

052060

SHIELD,hand

052

095

SCREW,

set

steel

socket

5/16-18

1/2

601

856

NUT,

weld

5/16-18

602

207

WASHER,

lock

steel

split

1/4

601

865

NUT,

steel

hex

full

1/4-20

052068

HANDLE,gun-right

hand

052088

CABLE/CONDUIT.

lOft

052089

CABLE/CONDUIT,

l5ft

052 090

CABLE/CONDUIT,

052091

CABLE/CONDUIT,l5ft

053

076

CLAMP,

hose

inch

clamp

dia

005

177

STRAIN

RELIEF

052

083

TUBING,

neoprene

5/8

3/32

waIl

052

063

CONNECTOR,

cable

gun

052

883

SCREW,

set

steel

socket

10-32

3/8

052

092

CABLE,

connecting

power

(MM-30

Series

only)

1 1

052

058

GUIDE,

wire

outlet

1/16

3/32

(MM-30

Series)

052056

ADAPTER,gun/feeder

1/16-3/32

(2900)

052 057

ADAPTER,

gun/feeder

1/16

5/64

(LN-22)

052

158

ADAPTER,

gun/feeder

1/16

3/32

(LN-8)

1 1

604

523

CAP,

twist

lock

midget

2P2W

073

329

PLUG,

97-3106A-18-4P

(2900)

073

331

CLAMP,

cable

(2900)

052236

PLUG,3pinMS-3106A-14S-1P(LN-22)

039

828

STRAIN

RELIEF,

receptacle/plug

(LN-22)

052237

PLUG,5

MS-3106A-18-11P

(LN-8)

073

332

CLAMP,

cable

(LN-8)

052086

CORD,trigger

ftor

052

087

CORD,

trigger

053132

STRAIN

RELIEF,cable

052084

LINER,monocoil

1/16-3/32wirex

ftor

052085

LINER,monocoil

1/16-3/32wirex

16ft

052

071

CLAMP,

head

tube

057

544

SPRING,

compression

1 1

052

919

SCREW,

machine

steel

round

1/4-20

7/8

Parts

For

Optional

Equipment

052 419

TUBE,

head

(12

inches)

052

837

LINER,

monocoil

1/1

6-3/32

wire

ft.

inches

SURE

PROVIDE

MODEL

AND

STYLE

NUMBERS

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-1515

Page

-~-Th

This manual suits for next models

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