Miller GA-17C User manual

June

1989

FORM:

OM-1

028

Millerﬁ

Effective

With

Style

No.

JK-34

MODEL

GA-17C

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

both

this

Miller

Electric

Mfg.Co.

manual

and

the

power

source

manual

used

with

this

unit,

with

special

AMOe~G,o~oLIaCorn~anv

emphasis

the

safety

material

throughout

both

manuals,

before

in-

P0.

Box

1079

stalling,

operating,

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

Appleton,

54912

USA

Tel.

414-734-9821

safe

operation

welding

equipment.

not

allow

untrained

persons

install,

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

instructions.

PRINTED

U.S.A.

ADDITiONAL

COPY

PRICE

CENTS

E

LIMITED

WARRANTY

EFFECTIVE:

MARCH

15,

1989

This

warranty

supersedes

all

MILLER

warranties

and

exclusivewith

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY



Subject

the

terms

and

conditions

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

warrants

its

Distributor/Dealer

that

all

new

and

unused

Equipment

fur

nished

Miller

free

from

defect

workmanship

andmaterial

the

time

and

place

delivery

Miller.

warranty

made

by Miller

with

respect

engines,

trade

accessories

other

items

manufactured

others.

Such

engines,

trade

cessories

and

other

items

are

sold

subject

the

warranties

their

respective

manufacturers,

any.

All

engines

are

war

ranted

their

manufacturer

for

one

year

from

date

original

purchase,

except

Tecumseh

and

Onan

engines

which

have

two

year

warranty.

Except

specified

below,

Millers

warranty

does

not

apply

components

having

normal

useful

life

less

than

one

(1)

year,

such

spot

welder

tips,

relay

and

contactor

points,

MILLER

MATIC

parts

that

come

contact

with

the

welding

wire

includ

ing

nozzles

and

nozzle

insulators

where

failure

does

not

result

from

defect

workmanship

material.

Miller

shall

required

honor

warranty

claims

warranted

Equipment

the

event

failure

resulting

from

defect

within

the

following

periods

from

the

date

delivery

Equipment

the

original

user:

Arc

welders,

power

sources,

robots,

and

year

components

Load

banks

year

Original

main

power

rectifiers

years

(labor



year

only)

All

welding

guns,

feeder/guns

and

torches

days

All

other

Millermatic

Feeders

year

Replacement

repair

parts,

exclusive

labor

days

Batteries

months

provided

that

Miller

notified

writing

within

thirty

(30)

days

the

date

such

failure.

matter

general

policy

only,

Miller

may

honor

claims

submitted

the

original

user

within

the

foregoing

periods.

the

case

Millers

breach

warranty

orany

other

duty

with

respect

the

quality

any

goods,

the exclusive

remedies

therefore

shall

be,

Millers

option

(1)

repair

(2)

replacement

or,

where

authorized

writing

Miller

appropriate

cases,

(3)

the

reasonable

cost

repair

replacement

author

ized

Miller

service

station

(4)

payment

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

the

goods

Customers

risk

and

expense.

MILLERs

option

repair

replacement

will

FOB.,

Fac

tory

Appleton,

Wisconsin,

FOB,

MILLER

authorized

service

facility,

therefore,

compensation

for

transportation

costs

any

kind

will

allowed.

Upon

receipt

notice

parent

defect

failure,

Miller

shall

instruct

the

claimant

the

warranty

daim

procedures

followed.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND ANY

IMPLIED

WARRANTY,

GUARANTY

REPRE

SENTATION

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

CUSTOM

TRADE

COURSE

DEALING,

INCLUDING

ANY

IMPLIED

WARRANTY

MERCHAN

TABILITY

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY AND

ALL

EQUIPMENT

FUR

NISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

EXCEPT

EXPRESSLY

PROVIDED

MILLER

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTI

MATE

PURCHASE

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

OPERATION

PERSONS

TRAINEDAND

EXPE

RIENCED

THE USE

AND

MAINTENANCE

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

CON

SUMER

USE.

MILLERS

WARRANTIES

NOT

EXTEND

TO,

AND

RESELLER

AUTHORIZED

EXTEND

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.



ERRATA

SHEET

**First

digit

represents

page

digits

following

dash

represent

item

no.

SURE TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

II9LE

COpy

R~II

URN

FOLDER

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

AMENDMENT

SECTION

PARTS

LIST

Amend

Parts

List

follows:

All

Parts

Eff

w/JK732707

Part

Replaced

No.

With

Descnptuon

Quantity

7-15

605

565

133

147

STRAIN,

relief

cable

7-16

128

721

133

352

CABLE/CONDUIT,

lOft

7-16

128

722

133

353

CABLE/CONDUIT,

l2ft

7-16

128

723

133

351

CABLE/CONDUIT,

15ft

SECTION

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1-1.

GENERAL

INFORMATION

AND

SAFETY

General

Information

presented

this

manual

and

various

bels,

tags,

and

plates

the

unit

pertains

equipment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

read,

understood,

and

followed

for

the

safe

and

effective

use

this

equipment.

Safety

The

installation,

operation,

maintenance,

and

trouble

shooting

arc

welding

equipment

requires

practices

and

procedures

which

ensure

personal

safety

and

the

safety

others.

Therefore,

this

equipment

stalled,

operated,

and

maintained

only

qualified

per

sons

accordance

with

this

manual

and

all

applicable

codes

such

as,

but

not

limited

to,

those

listed

the

end

Section



Safety

Rules

For

Operation

Arc

Weld

ing

Power

Source

the

welding

power

source

Owners

Manual.

1-2.

SAFETY

ALERT

SYMBOL

AND

SIGNAL

WORDS

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

call

attention

and

identify

different

levels

hazard

and

special

instruc

tions.

This

safety

alert

symbol

used

with

the

signal

words

WARNING

and

CAUTION

call

atten

tion

the

safety

statements.

WARNING

statements

identify

procedures

practices

which

must

followed

avoid

seri

ous

personal

injury

loss

life.

CAUTION

statements

identify

procedures

practices

which

must

followed

avoid

minor

personal

injury

damage

this

equipment.

IMPORTANT

statements

identify

special

instructions

necessary

for

the

most

efficient

operation

this

equip

ment.

SECTION

INTRODUCTION

Table

2-1.

SpecificatIons

Ampere

Ratina

60%

Duty

Cycre

Wire

Diameter



Cable

Length

Coolina

Method

Weight

Net

Ship

170

Amoeres

With

~O2

0.023

0.035

in.

(0.6

0.9

mm)

lOft.

(3.0

ft.

(3.7

ft.

(4.6

Air

3.5

lbs.

(1.6

kg)

lbs.

(2.7

kg)

lbs.

(1.8

kg)

6.5

lbs.

kg)

4.5

lbs.

kg)

lbs.

(3.2

kg)

2-1.

DUTY

CYCLE

The

duty

cycle

welding

gun

the

percentage

ten

minute

period

that

gun

can

operated

given

output

without

overheating

and

damaging

the

gun.

This

gun

rated

60%

duty

cycle

using

C02

shielding

gas.

This

means

the

gun

can

operated

170

amperes

for

six

minutes

out

ten

with

C02

shielding

gas.

During

the

remaining

four

minutes,

the

gun

must

operate

load

permit

proper

cooling.

rated

amperage

exceeded,

the

duty

cycle

must

reduced.

CAUTION:

EXCEEDING

THE

RATED

PERAGE

WITH

CO2

FAILING

DUCE

THE

WELDING

AMPERAGE

DUTY

CYCLE

WHEN

USING

MIXED

SHIELDING

GAS

can

result

damage

the

gun.



not

exceed

rated

amperage

when

using

CO2.



Operate

30%

duty

cycle

when

using

mixed

shielding

gas.

2-2.

DESCRIPTION

This

unit

air-cooled

semiautomatic

Gas

Metal

Arc

Welding

(GMAW)

gun.

The

alpha-numeric

designation

refers

the

following:

G-Gun



Air

Cooled

17Ampere

Rating:

170

Amperes

CCurved

HeadTube

OM-1028

Page

SECTION

INSTALLATION

Contact

Tube

Nozzle

Contact

Tube

Adapter

Figure

3-1.

Gun

Components

Connector

TB.124

473

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

ilve

electrical

parts.



Shut

down

welding

power

source

and

wire

feeder,

and

disconnect

input

power

employing

locko

uttagging

procedures

before

inspecting

installing

gun.

Lockout/tagging

procedures

consist

remov

ing

input

power

plug

from

receptacle,

padlock

ing

line

disconnect

switch

open

position,

moving

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnect

ing

device.

3-1.

GUN/WIRE

FEEDER

CONNECTIONS

(Figure

3-1)

Install

the

gun/feeder

connector

into

the

drive

assembly

the

wire

feeder

follows:

IMPORTANT:

The

wire

outlet

guide

pro

vided

part

the

gun

assembly.

Loosen

the

gun/feeder

connector

securing

knob

the

wire

drive

assembly.

IMPORTANT:

Wire

guides

should

positioned

possible

the

drive

rolls

without

touching

them.

This

gives

wire

maximum

column

strength.

Monocoll

Liner

Trigger

Switch

Gun

Switch

Plug

Wire

Outlet

Guide

OM-1028

Page

Insert

gun

into

wire

drive

assembly

until

gun/feeder

connector

stops

against

wire

drive

assembly.

Tighten

gun/feeder

connector

securing

knob.

3-2.

GUN

SWITCH

CONNECTION

(FIgure

3-1)

Connect

gun

trigger

switch

into

TRIGGER

receptacle

wire

feeder

follows:

align

keyways,

insert

plug,

and

rotate

threaded

collar

fully

clockwise.

SECTION

SEQUENCE

OPERATION

4-1.

GAS

METAL

ARC

WELDING

(GMAW)

WARNING:

ELECTRIC

SHOCK

can

kill;

MOVING

PARTS

can

cause

serious

Injury;

IMPROPER

AIRFLOW

AND

EXPOSURE

ENVIRONMENT

can

damage

Internal

parts.



not

touch

live

electrical

parts.



not

touch

welding

wire

any

metal

part

contact

with

the

wire

while

welding.

The

welding

wire

and

all

metal

parts

contact

with

carry

wed

output

when

the

gun

switch

depressed.



Keep

all

covers

and

panels

place

while

erating.

Warranty

void

the

welding

power

source

operated

with

any

portion

the

outer

enclosure

removed.

ARC

RAYS,

SPARKS,

AND

HOT SURFACES

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

correct

eye,

ear,

and

body

protection.

FUMES

AND

GASES

can

seriously

harm

your

health.



Keep

your

head

Out

the

fumes.



Ventilate

keep

from

breathing

fumes

and

gases.



ventilation

inadequate,

use

approved

breathing

device.

WELDING

WIRE

can

cause

puncture

wounds.



not

point

gun

toward

any

part

the

body,

any

conductive

surface,

other

personnel.

HOT

METAL, SPATTER,

AND

SLAG

can

cause

fire

and

burns.



Watch

forfire.



Keep

fire

extinguisher

nearby,

and

know

how

use

it.



not

use

near

flammable

material.



Allow

work

and

equipment

coo/before

han

dling.

MAGNETIC

FIELDS

FROM

HIGH

CURRENTS

can

affect

pacemaker

operation.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

orspot

welding

~operations.

See

Section

Safety

Rules

For

Operation

Arc

Welding

Power

Source

welding

power

source

Owners

Manual

for

basic

welding

safety

information.

sure

that

proper

electrical

connections

have

been

made

the

welding

power

source,

and

the

wire

feeder.

sure

that

the

welding

wire

has

been

properly

threaded

and

that

correct

initial

tensions

have

been

set

the

drive

rolls

(refer

the

appropriate

Own

ers

Manual).

sure

that

the

proper

shielding

gas

connected

the

shielding

gas

valve.

Place

the

wire

feed

control(s)

the

required

posi

tion

for

the

welding

setup.

Place

the

controls

the

welding

power

source

the

required

position

for

the

welding

setup

(refer

welding

power

source

Owners

Manual).

Wear

dry

insulating

gloves

and

clothing,

and

wear

welding

helmet

with

proper

filter

lens

according

ANSI

Z49.1.

Prepare

for

welding

follows,

connect

work

clamp

clean,

bare

metal

workpiece.

Turn

the

shielding

gas

supply.

Energize

the

welding

power

source

and

the

wire

feeder

(refer

the

respective

Owners

Manual).

IMPORTANT:

When

installing

new

equipment,,

orafter

prolongedshutdown,

allowshielding

gas

flowcontinu

ously

forat

least

one

minute

before

welding

purge

the

shielding

gas

line.

avoid

wasting

wire

while

purging,

open

the

drive

roll

housing.

10.

Press

Purge

button

the

wire

feeder

(if

applicable)

the

gun

switch

purge

the

gas

line.

11.

drive

roll

housing,

and

adjust

tension

(see

propriate

Owners

Manual).

12.

Press

the

gun

trigger,

and

run

the

welding

wire

out

beyond

the

end

the

gas

nozzle.

Cut

the

wire

off

extends

out

1/4

3/8

in.

(6.4

9.5

mm)

from

end

nozzle.

13.

Set

the

Wire

Speed

control

slightly

higher

than

ticipated

wire

speed.

14.

Hold

the

end

the

gas

nozzle

approximately

1/2

in.

(12.7

mm)

from

the

workpiece.

15.

Press

the

gun

trigger.

Gas

starts

flow,

wire

starts

feed,

and

the

arc

will

established.

the

welding

wire

appears

slip,

adjust

drive

roll

tension

accord

ing

wire

feeder

Owners

Manual.

OM-1028

Page

16.

After

the

controls

the

welding

power

source

and

the

wire

feeder

(if

applicable)

have

been

adjusted

for

normal

operation,

the

welding

power

source

(and

wire

feeder)

will

function

automatically

when

the

gun

trigger

pressed.

Releasing

the

gun

trigger

will

tinguish

the

arc

and

cause

the

wire

feed

and

gas

flow

stop.

4-2.

SHUTTING

DOWN

Stop

welding.

Turn

off

welding

power

source

and

wire

feeder.

Turn

off

the

shielding

gas

its

source.

5-1.

INSPECTION

AND

UPKEEP

Usage

and

shop

conditions

will

determine

frequency

and

type

maintenance

required.

WARNING:

ELECTRIC

SHOCK

can

kill;

WELDING

WIRE

can

cause

puncture

wounds;

HOT

SURFACES

can

cause

severe

burns.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

wire

feeder

before

working

gun.



Disconnect

gun

from

wire

feeder

before

specting,

maintaining,

servicing.



Allow

cooling

period

before

servicing.

Inspect

gun

for

broken

areas,

cracks

and

loose

parts:

tighten,

repair

and

replace

required.

Carefully

remove

any

weld

spatter

dirt

that

has

accumulated

around

nozzle

opening

and

inside

nozzle.

Repair

replace

required

all

hose

and

cables;

give

particular

attention

frayed

and

cracked

insu

lation

and

areas

where

enters

equipment.

Remove

grease

and

grime

from

components

and

moisture

from

electrical

parts

and

cables.

Blow

out

casing

with

compressed

airwhen

changing

wire.

This

removes

any

loose

metal

chips

and

dirt

that

may

have

accumulated.

CAUTION:

FLYING

DIRT

AND

METAL

PARTI

CLES

can

Injure

personnel

and

damage

equIpment.



PoTht

gun

liner

only

safe

direction

away

from

personnel

and

equipment

when

cleaning

with

compressed

air.

5-2.

CONTACT

TUBE

REPLACEMENT

(Figure

3-1)

WARNING:

ELECTRIC

SHOCK

can

kill;

WELDING

WIRE

can

cause

puncture

wounds;

HOT

SURFACES

can

cause

severe

burns.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

wire

feeder

before

working

gun.



Disconnect

gun

from

wire

feeder

before

specting,

maintaining,

servicing.



Allow

cooling

period

before

servicing.

Remove

nozzle.

slight

twist

clockwise

aids

moval

and

installation.

Cut

off

any

portion

electrode

wire

which

extends

beyond

end

contact

tube.

Remove

contact

tube,

and

replace

with

new

contact

tube.

Reinstall

nozzle,

and

resume

operation.

5-3.

CHANGING

WIRE

SIZES

AND

REPLACING

LINER

WARNING:

ELECTRIC

SHOCK

can

kIll;

WELDING

WIRE

can

cause

puncture

wounds;

HOT

SURFACES

can

cause

severe

burns.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

wire

feeder

before

working

gun.



Disconnect

gun

from

wire

feeder

before

specting,

maintaining,

servicing.



Allow

cooling

period

before

servicing.

IMPORTANT:

.030

and

.035

in.

(0.8

and

0.9

mm)

ameter

wires

use

the

same

monocoll

liner

and

outlet

guide.

Changing

from

.030

in.

(0.8

mm)

wire

.035

in.

(0.9

mm)

wire

vice

versa

requires

changing

the

con

tact

tube

only

(see

Section

5-2).

change

from

.030

in.

(0.8

mm)

wire

.035

in.

(0.9

mm)

wire

.023

(0.6mm)

wire

vice

versa,

place

monocoil

liner,

proceed

follows:

Remove

nozzle.

slight

twist

clockwise

aids

moval

and

installation.

Cut

off

any

portion

electrode

wire

which

extends

beyond

end

contact

tube.

CAUTION:

LOOSE

WELDING

WiRE

can

cause

Injury.



Keep

firm

hold

the

wire

during

installa

tion,

removal,

and

threading

operations.

Spooled

wire

has

tendency

unravel

rapidly

when

loosened

from

the

spool.

WARNING:

HIGH

CONCENTRATION

SHIELDING

GAS

can

harm

health

kill.



Shut

off

gas

supply

when

not

use.

SECTION

MAINTENANCE

OM-1028

Page

Manually

retract

wire

onto

wire

spool

(see

wire

feeder

Owners

Manual).

Remove

contact

tube

and

contact

tube

adapter.

Disconnect

gun

assembly

from

wire

feeder,

appli

cable,

and

lay

out

flat

(no

coils

cable/conduit).

Remove

outlet

guide.

Pull

Out

monocoil

liner

from

gun/feeder

connector

end

gun

assembly.

CAUTION:

FLYING

DIRT

AND

METAL

PAR

TICLES

can

Injure

personnel

and

damage

equipment.



Point

gun

liner

only

safe

direction

away

from

personnel

and

equipment

when

cleaning

with

compressed

air.

Clean

gun

casing

liner

with

compressed

air

while

liner

welding

wire

removed.

Insert

new

monocoil

liner

into

gun/feeder

end

gun

assembly.

sure

monocoil

covered

with

tub

ing

the

gun/feeder

connector.

10.

Insert

newoutlet

guide

that

1/8

in.

(3mm)

liner

sticks

out.

Tighten

outlet

guide.

CAUTION:

OVERTIGHTENING

OUTLET

GUIDE

damages

liner.



not

overtighten

outlet

guide.

11.

Cut

off

liner

that

3/8

in.

(9.5

mm)

liner

sticks

out

the

head

tube.

12.

install

contact

tube

adapter.

13.

Reinstall

appropriate

contact

tube

and

nozzle.

14.

Reinstall

gun

wire

drive

assembly.

15.

Thread

welding

wire

according

the

wire

feeder

Owners

Manual,

and

resume

operation.

OM-1028

Page

SECTION

PARTS

LIST

Figure

6-1.

Exploded

View

GA-17C

Gun

TC-124

605-A

OM-1028

Page

Table of contents

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