OM-210 089D June 1999 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder MW 135 / MW 175 And GA16C2 Gun
TABLE OF CONTENTS The following terms are used interchangeably throughout this manual: MIG=GMAW OM-210089D SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 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 1. CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_Fre_4/97 1.1 Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité. 1.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.
1.3 Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D Rester à l’écart des organes mobiles comme le ventilateur. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
1.4 Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W.
SECTION 2 – SPECIFICATIONS 2-1. Specifications A. 120 VAC Model Rated Welding Output Amperage Range Maximum OpenCircuit Voltage DC KVA KW Weight W/ Gun Overall Dimensions Length: 19-1/8 in (489 mm) 90 A @ 19 Volts DC, 30% Duty Cycle 30 – 130 24 2.88 2.45 20* 2.40* 2.
2-2. 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 duty cycle before welding. A. 120 VAC Model Y Exceeding duty cycle can damage unit or gun and void warranty. 30%dutycycle at 90 amps 3 Minutes Welding 7 Minutes Resting B.
2-3. Volt-Ampere Curves A. 120 VAC Model The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. B. 230 VAC Model ssb1.
SECTION 3 – INSTALLATION 3-1. Installing Welding Gun 1 2 3 4 Drive Assembly Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. Tighten thumbscrew. 4 2 Gun Trigger Leads Insert leads, one at a time, through small grommet on front panel. Connect female friction terminals to matching male terminals in unit. Polarity is not important. 3 Close door. 1 Ref. ST-802 024 3-2.
3-4. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Tools Needed: 5/8, 1-1/8 in Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 1 2 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical.
3-5. Selecting A Location And Connecting Input Power For 120 VAC Model 1 2 A 120 volt, 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required. 18 in (460 mm) 1 Rating Label Grounded Receptacle 2 3 Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m). 3 Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20.
3-6. Selecting A Location And Connecting Input Power For 230 VAC Model 1 Rating Label Supply correct input power. 2 3 Plug Receptacle Connect plug to receptacle. 4 18 in (457 mm) of space for airflow 4 Line Disconnect Device See Section 3-7. Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. L1 L2 Y Always connect grounding conductor first.
3-7. Electrical Service Guide For 230 VAC Model Input Voltage 230 Input Amperes At Rated Output 19.5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 30 Min Input Conductor Size In AWG/Kcmil 14 Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min Grounding Conductor Size In AWG/Kcmil 14 Reference: 1996 National Electrical Code (NEC) S-0092-J 3-8.
3-9. Threading Welding Wire 1 2 3 4 5 6 7 4 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. 7 Tools Needed: 1 2 3 5 6 . Hold wire tightly to keep it from unraveling. 4 in (102 mm) 6 in (150 mm) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Tighten INPUT POWER Close and tighten pressure assembly, and let go of wire.
SECTION 4 – OPERATION 4-1. Controls 1 Voltage Switch The higher the selected number, the thicker the material that can be welded (see weld setting label in welding power source or Sections 4-2 and 4-3, as applicable). Do not switch under load. 2 Voltage Switch - Purge “0” Position In purge position, fan runs but there is no weld output. 3 Wire Speed Control Use control to select a wire feed speed.
4-2. Weld Parameters For 120 VAC Model 205406A Welding Guide Settings are approximate. Adjust as required.
4-3. Weld Parameters For 230 VAC Model Welding Guide TO WELD: Settings are approximate. Adjust as required. THICKNESS WIRE (Inches/ GAS TYPE\SIZE Gauge) Auto Body Lawnmower Handles, Wagons, Tricycles, Duct Work, Auto Door Brackets, Tailpipes, Bicycles Wheelbarrows, Lawnmower Decks, Basketball Posts, Galvanized Roofing, Trailer Sides, Garage Door Tracks, Tailpipes, Motorcycles HB–28 (.024) CO2 or C25 20 3/64” 18 GA. HB–28 (.024) HB–28 (.030) CO2 or C25 20 20 1/16” 16 GA. 1/8” 11 GA.
SECTION 5 – MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y 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 5-2. Overload Protection 3 2 1 Circuit Breaker CB Circuit breaker CB protects wire feed motor from overload. If circuit breaker opens, wire stops feeding.
5-3. Changing Drive Roll Or Wire Inlet Guide 1 2 Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 3 4 2 Drive Roll The drive roll consists of two different sized grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to thread (see Section 3-9).
5-5. Cleaning Or Replacing GA16C2 Gun Liner Turn off welding power source/wire feeder. 3/8 in Remove nozzle, contact tip, and liner collet. 3/8 in Remove liner Gun/feeder connector Blow out gun casing. To Reassemble Gun: Install contact tip. Insert new liner. Tools Needed: Install collet onto liner and tighten into gun/feeder connector using wrench. Cut liner off near collet so that liner end is as close to drive rolls as possible without touching. 3/8 in Install nozzle. Ref.
5-6. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 3-5). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 4-1). Check circuit breaker CB (CSA model), and reset if necessary (see Section 5-2). No weld output; wire does not feed; fan Thermostat S3 open (overheating).
SECTION 6 – ELECTRICAL DIAGRAM 53 ST-205 400 Figure 6-1.
53 Overload Feed Motor ST-210 011-C Figure 6-2.
53 53 ST-205 423-B Figure 6-3.
SECTION 7 – MIG WELDING (GMAW) GUIDELINES 7-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.
7-2. Typical MIG Process Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or .125 in Convert Material Thickness to Amperage (A) (.001 in = 1 ampere) .125 in = 125 A .035 in Wire Size Amperage Range .023 in 30 – 90 A .030 in .
7-3. Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam.
7-4. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.
7-5. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 1 1 2 2 3 Stringer Bead – Steady Movement Along Seam Weave Bead – Side To Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. 3 S-0054-A 7-6.
7-8. Troubleshooting – Excessive Spatter Excessive Spatter – scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use shorter electrode extension (stickout). Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
7-11. Troubleshooting – Lack Of Penetration Lack Of Penetration – shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics. Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
7-14. Troubleshooting – Waviness Of Bead Waviness Of Bead – weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support hand on solid surface or use two hands. 7-15. Troubleshooting – Distortion Distortion – contraction of weld metal during welding that forces base metal to move.
7-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
Notes OM-210 089 Page 37
SECTION 8 – PARTS LIST 64 . Hardware is common and not available unless listed. ST-802 066-A Figure 8-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Main Assembly . . . 1 . . . . . . . . . . . . . . . +203 563-1 . . . PANEL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . . . . . . 204 036 . . . LABEL, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 3 . . . . . . . . . . . . . . . . . . 205 388 . . . PANEL, interior . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Main Assembly (Continued) . . . 49 . . . . . . . . . . . . . . . . . . 129 696 . . . . . . 50 . . . . . . . . . . . . . . . . . . 409 477 . . . . . . 51 . . . . . . . . . . . . . . . 361 052-10 . . . . . . 51 . . . . . . . . . . . . . . . 361 052-10 . . . . . . 52 . . . . . . . . . . . . . . . . . . 205 405 . . . . . . 52 . . . . . . . . . . . . . . . . . . 205 405 . . . . . . 53 . . . . . . . . . . . . . . . 405 278-11 . . . . . . 53 . . .
Item No. Part No. Description Figure 8-2. Complete Assembly (GA16C2 Gun) 187 708 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 8 9 9 9 10 11 12 13 14 15 Quantity . . . . . . . . . . 110 793 . . . . . . . . . . 110 795 . . . . . . . . . . 110 780 . . . . . . . . . . 110 779 . . . . . . . . . . 110 781 . . . . . . . . . . 128 878 . . . . . . . . ♦118 570 . . . . . . . . M154 822 . . . . . . . . M154 821 . . . . . . . ♦M154 826 . . . . . . . ♦M154 825 . . . . . .
OM-210 089 Page 42
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.
