Miller GA-5OGL User manual

Millerﬁ

August

1990

FORM:

OM-1532B

Effective

With

Style

No.

KA-27

MODEL::

GA-5OGL

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

both

this

manual

and

the

power

source

manual

used

with

this

unit,

with

special

emphasis

the

safety

material

throughout

both

manuals,

before

installing,

operating,

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

safe

operation

welding

equip

ment.

not

allow

untrained

persons

install,

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

instructions.

MILLER

ELECTRIC

Mfg.

Miller

Group

Ltd.,

Company

P.O.

Box

1079

Appleton,

WI 54912

USA

Tel.

414-734-9821

B-045

t14

PRINTED

U.S.A.

I

LIMITED

WARRANTY

EFFECTIVE:

AUGUST

1990

This

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guaTantees

warranties

expressed

implied.

LIMITED

WARRANTY



Subject

the

terms

and

conditions

hereof,

MILLER

Electric

Mfg.

Co.

Appleton,

Wisconsin

war

rants

its

Distributor/Dealer

that

all

new

and

unused

Equipment

furnished

MILLER

free

from

defect

workmanship

and

material

the

time

and

place

delivery

MILLER.

warranty

made

MILLER

with

respect

engines,

trade

accessories

other

items

manufactured

others.

Such

engines,

trade

accessories

and

other

items

are

sold

subject

the

warranties

their

respective

manufacturers,

any.

All

engines

are

warrantied

their

manufacturer

for

two

years

from

date

original

purchase,

except

Deutz

engines

which

have

one

year,

2000

hour

warranty.

Except

specified

below,

MILLERs

warranty

does

not

apply

components

having

normal

useful

life

less

than

one

(1)

year,

such

spot

welder

tips,

relay

and

contactor

points,

MILLERMATIC

parts

that

come

contact

with

the

welding

wire

including

nozzles

and

nozzle

insulators

where

failure

does

not

result

from

defect

workmanship

material.

MILLER

shall

required

honor

warranty

claims

war

ranted

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

any

other

duty

with

respect

the

quality

any

goods,

the

exclusive

remedies

therefore

shall

be.

MILLERs

option

(1)

repair

(2)

replace

ment

or,

where

authorized

writing

MILLER

appropriate

cases,

(3)

the

reasonable

cost

repair

replacement

authorized

MILLER

service

station

(4)

payment

credit

for

the

purchase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

the

goods

Customers

risk

and

expense.

MILLERs

option

repair

replacement

will

F.O.B.,

Factory

Appleton,

Wisconsin.

FOB.

MILLER

authorized

service

facility,

therefore,

compensation

for

transportation

costs

any

kind

will

allowed.

Upon

receipt

notice

apparent

defect

failure,

MILLER

shall

instruct

the

claimant

the

warranty

claim

procedures

followed.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WARRANTY,

GUARANTY OR

REPRE

SENTATION

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

CUSTOM

OF TRADE

OR COURSE

DEALING,

INCLUDING

ANY

IMPLIED

WARRANTY

MERCHAN

TABILITY

F!TNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

ALL

EQUIPMENT

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

EXCEPT

EXPRESSLY

PROVIDED

MILLER

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTIMATE

PURCHASE

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

OPERATION

PERSONS

TRAINED

AND

EXPERIENCED

THE

USE

AND

MAINTENANCE

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

CONSUMER

USE.

MILLERS

WARRANTIES

NOT

EXTEND

TO,

AND

RESELLER

AUTHORIZED

EXTEND

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

I

March

16,

1992

FORM:

OM-1532

ERRATA SHEET

___________________

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

to-data

appearing

later

this

manual.

AMENDMENT

SECTION

5

MAINTENANCE

Add

the

following

IMPORTANT

block

the

beginning

Section

5-3.

CHANGING

WIRE

SIZES

IMPORTANT:

Guns

shipped

for

use

with

1/16,

.0687.072,

5/64

in.

(1.6,

1.8,

or2.

mm)

wire

not

have

stub

lin~

the

head

tube.

When

changing

larger

wire

size,

stub

liner

must

inserted

into

the

head

tube.

Guns

shipped

for

use

with

3/32,

7/64,

1/8

in.

(2.4,

2.8,

3.2

mm)

wire

have

stub

liner

the

head

tube.

When

changing

smaller

wire

size,

the

stub

liner

removed

and

the

monocoll

liner

goes

through

the

head

tube.

AMENDMENT

SECTION

8

PARTS

LIST

Amend

Parts

List

follows:

Part

Replaced

No.

With

Description

Quantity

Added

....

008

931

LINER,

monocoil

3/32-1/8

wire

7.250

7-26

...

008

759

....

088

759

LINER,

monocoil

3/32-1/8

wire

l5ft

~First

digit

represents

page



digits

following

dash

represent

item

no.

SURE

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-15329

8/90

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

forany

dam-

Use

the

following

spaces

record

the

Model

Designa

age

that

may

have

occurred

during

shipment.

File

any

tion

and

Serial

Style

Number

your

unit.

The

infor

claims

for

loss

damage

with

the

delivering

carrier.

mation

located

the

data

card

the

nameplate.

Assistance

for

filing

settling

claims

may

obtained

from

the

distributor

and/or

the

equipment

manufactur-

Model

_________________________________

ers

Transportation

Department.

Serial

Style

No.

When

requesting

information

about

this

equipment,

ways

provide

the

Model

Description

and

Serial

Style

Date

Purchase

_____________________

Number.

TABLE

CONTENTS

Section

No.

Page

No.

SECTION



SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1-1

General

Information

And

Safety

1-2

Safety

Alert

Symbol

And

Signal

Words

SECTION

2

SPECIFICATIONS

2-1.

Duty

Cycle

2-2.

Description

SECTION

3INSTALLATION

3-1.

Gun/Feeder

Connector

Installation

3-2.

Nozzle

(Optional)

3-3.

Installation

Trigger

Switch

(Optional)

SECTION

4SEQUENCE

OPERATION

4-1.

Flux

Cored

And

Manual

Submerged

Arc

Welding

4-2.

Shutting

Down

SECTION

5

MAINTENANCE

5-1.

Inspection

And

Upkeep

5-2.

Contact

Tube

Replacement

5-3.

Changing

Wire

Sizes

SECTION

6

PARTS

LIST

Figure

6-1

Exploded

View

Gun

(Gun

With

1/16

Wire

Illustrated)

LIST

CHARTS

AND

TABLES

Table

2-1.

Specifications

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

forthe safe

and

effective

use

this

equipment.

Safety

The

installation,

operation,

maintenance,

and

trouble

shooting

of.

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.

1-2

SAFETY

ALERT

SYMBOL

AND

SIGNI

WORDS

The

following

safety

alert

symbol

and

signal

words

used

throughout

this

manual

call

attention

and

ide

tify

different

levels

hazard

and

special

instructions

This

safety

alert

symbol

used

with

the

sigr

words

WARNING

and

CAUTION

call

atte

tion

the

safety

statements.

WARNING

statements

identify

procedures

practices

which

must

followed

avoid

ous

personal

injury

loss

life.

CAUTION

statements

identify

procedures

practices

which

must

followed

avoid

mir

personal

injury

damage

this

equipment.

IMPORTANT

statements

identify

special

instructiohs

necessary

for

the

most

efficient

operation

this

equ

-

ment.

SECTION

SPECIFICATIONS

Table

2-1.

SpecificatIons

2-1.

DUTY

CYCLE

The

duty

cycle

awelding

gun

the

percentage

ten

minute

period

that

gun

can

operated

given

out

put.

This

gun

rated

100

percent

duty

cycle.

This

means

that

the

gun

can

operated

rated

load

con

tinuously

with

the

self-shielding

Flux

Cored

Arc

Welding

proces

The

gun

shipped

with

the

necessary

components

the

specificwire

size

ordered.

Through

minorchanges

parts

the

gun

may

used

with

1/16,

.068/.072,

5/6

3/32,

7/64,

1/8

in.

(1.6,

1.8,

2.0, 2.4,

2.8,

3.2

flux

cored

wire.

The

GA-5OGL

designed

for

semiaut

matic

scratch

start

open

arc

welding.

The

alpha-numeric

designation

refers

the

followin

G-gun

air

cooled

ampere

rating:

500

ampere

gasless

1

Rating:

100%

Duty

Cycle,

dcrl4

Wire

Diameter

Cable

Length

Cooling

Method

Net

Weight

Ship

Weight

500

Amperes

1/16

thru

1/8

in.

(1.6thru3.2mm)

lOft.

3.0

15ft.

4.6m

Air

lbs.

l4lbs.

5.4

6.4kg

lbs.

6.4

l6lbs.

7.3kg

CAUTION:

EXCEEDING

DUTY

CYCLE

RAT

ING

will

damage

the

welding

gun.



not

exceed

rated

duty

cycle.

2-2.

DESCRIPTION

This

gun

designed

specifically

for

use

conjunction

OM-1532

Page

SECTION

3

INSTALLATION

Contact

Tube

Figure

3-1.

Gun

Components

Ref.

TC-044

585

Thread

~Head

Tube

Clamp

Head

Tube

Connector

Liner

Lubricator

Cup

Outlet

Guide

Rear

Centering

Sleeve

Setscrew

Gun

Handle

Liner

Insulator

OM-1532

Page

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shut

down

wire

feeder

and

welding

power

source

and

disconnect

input

power

employing

locko

ut/tagging

procedures

before

inspecting

installing

gun.

Lockout/tagging

procedures

consist

padlocking

line

disconnect

switch

open

posi

tion,

removing

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

dis

connecting

device.

3-1.

GUN/FEEDER

CONNECTOR

INSTALLATION

(Figure

3-1)

Proceed

follows

install

the

gun/feeder

connector

into

the

drive

assembly

the wire

feeder.

IMPORTANT:

The

outlet

guide

pro

videdas

part

the

gun

assembly.

Loosen

the

gun/feeder

connector

securing

knob

the

wire

drive

assembly.

IMPORTANT:

The

outlet

guide

should

positioned

possible

the

drive

rolls

without

touching

them.

This

gives

the

wire

maximum

column

stren~

thus

ellminating

waves.

Insert

the

gun/feeder

connector

into

the

wire

dri

assembly.

Tighten

the

gun/feeder

connector

securing

knob.

3-2.

NOflLE

(Optional)

1-3/4

in.

(44.5

mm)

nozzle

recommended

for

norrr

application.

longer

stick

out

the

electrode

desire

2-3/8

in.

(60

mm)

nozzle

available.

The

gun

shipped

with

thread

protector

which

should

when

nozzle

not.

3-3.

INSTALLATION

TRIGGER

SWITCH

tlonal)

IMPORTANT:

The

installation

trigger

switch

ada~

the

GA-5OGL

gun

for

use

with

any

feeder

requiring

switch-type

starting

system.

Position

the

triggerswitch

the

gun

handle

and

cure

with

supplied

clamp.

Insert

the

amphenol

gun

switch

plug

into

the

switc~h

control

receptacle

the

wire

feeder.

Rotate

the

plug

collar

clockwise

lock

plug

receptacle.

SECTION

4

SEQUENCE

OPERATION

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.



Keep

away

from

moving

parts.



Keep

all

covers

and

panels

place

while

operating.

Warranty

void

the

wire

feeder

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

beathing

fumes

and

gases.



ventilation

inadequate,

use

approved

breathing

device.

WELDING

WIRE

can

cause

puncture

wounds.



not

point

gun

ward

any

part

the

body,

any

conductive

surface,

other

personnel.

HOT

METAL,

SPATTER,

AND

SLAG

can

cause

fire

and

burns.



Watch

for

fire.



Keep

fire

extinguisher

nearby,

and

know

how

use

it.



not

use

near

flammable

material.



Allow

work

and

equipment

cool

for

handling.

MAGNETIC

FIELDS

FROM

HIGH

CURREN

can

affect

pacemaker

operation.



Wearers

should

consult

their

doctor

befof

going

near

arc

welding,

gouging,

orspot

weldis~

opera

tions.

See

Section

Safety

Rules

For

Operation

Arc

Welding

Power

Source

the

welding

pow

source

Owners

Manual

for

basic

welding

safe

information.

4-1.

FLUX

CORED

AND

MANUAL

SUBMERGE

ARC

WELDING

Ensure

that

proper

electrical

connections

hay

been

made

the

welding

power

source

and

wire

feeder.

Ensure

that

the

welding

wire

has

been

properi

threaded

and

that

correct

initial

tension

has

been

the

drive

rolls

(refer

the

wire

feeder

Owner:

Manual).

Place

control(s)

wire

feeder

the

desired

pos

tion

for

the

welding

setup.

OM-1532

Page

f/i

:1,

)

Place

the

controls

the

welding

power

source

the

desired

position

for

the

welding

setup

(refer

welding

power

source

Owners

Manual).

Energize

the

welding

power

source

and

wire

feeder

(refer

the

respective

Owners

Manuals).

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

wire

feeder,

and

disconnect

gun

before

hand/mg

rep/acing

any

gun

parts.



When

not

use,

store

the

gun

insulated

holder

wire

cannot

touched

make

contact

with

metal

surfaces.



Wear

dry

insulating

gloves

and

use

insu

lated

tools

when

cutting

wire.

The

welding

wire

andailmetal

parts

contact

with

are

electrically

hot

whenever

the

wire

feeder

connected

energized

welding

power

supply.

Actuate

jog

switch

optional

Trigger

Switch,

plicable,

run

the wire

out

beyond

the

end

the

contact

tube.

Cut

the

wire

off

sticks

out

approxi

mately

1/2to

3/4

in.

(13

mm)

from

the

nozzle..

Hold

end

nozzle

approximately

in.

(25

mm)

from

workpiece.

Touch

welding

wire

workpiece

press

optional

Trigger

Switch,

applicable,

start

wire

feed;

arc

will

established.

wire

slippage

noticed,

tighten

drive

roll

pressure

adjustment

1/4

turn

time

until

slippage

stops.

not

overtighten.

After

the

controls

the

welding

power

source

and

wire

feeder

are

adjusted

for

normal

operation,

they

will

function

automatically

whenever

the

welding

wire

touches

the

workpiece

the

optional

Trigger

Switch

depressed.

Removing

welding

wire

from

workpiece

releasing

the

Trigger

Switch,

applica

ble,

will

break

the

arc

and

cause

wire

feeder

stop.

4-2.

SHUTTING

DOWN

Stop

welding

(remove

wire

from

workpiece).

Turn

off

welding

power

source

and

wire

feeder.

SECTION

5

MAINTENANCE

WARNING:

ELECTRIC

SHOCK

can

kill;

MOVING

PARTS

can

cause

serious

injury;

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.



When

not

use,

store

the

gun

insulated

holder

wire

cannot

touched

make

con

tact

with

metal

surfaces.



Disconnect

gun

from

wire

feeder

before

specting,

maintaining,

servicing.



Allow

cooling

period

before

servicing.

5-1.

INSPECTION

AND

UPKEEP

Usage

and

shop

conditions

will

determine

frequency

and

type

maintenance

required.

Inspect

gun

for

broken

area,

cracks

and

loose

parts;

tighten,

repair,

and

replace

required.

Carefully

remove

any

weld

spatter

orforeign

matter

which

may

accumulate

around

the

nozzle

orifice.

Remove

any

accumulation

around

the

Trigger

Switch,

applicable.

Repair

replace

required

all

cables;

give

par

ticular

attention

frayed

and

cracked

insulation

and

areas

where

enters

equipment.

Remove

grease

and

grime

from

components;

mois

ture

from

electrical

parts

and

cables.

5-2.

CONTACT

TUBE

REPLACEMENT

(Figure

3-1)

WARNING:

ELECTRIC

SHOCK

can

kill;

MOVING

PARTS

can

cause

serious

injury;

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.



When

not

use,

store

the

gun

insulated

holder

wire

cannot

touched

make

con

tact

with

metal

surfaces.



Disconnect

gun

from

wire

feeder

before

specting,

maintaining,

servicing.



Allow

cooling

period

before

servicing.

Remove

nozzle.

Cut

off

any

portion

the

electrode

wire

which

tends

beyond

end

contact

tube.

Remove

contact

tube

and

replace

with

new

contact

tube.

Replace

nozzle

and

resume

operation.

OM-1532

Page

Table of contents

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