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
20
CENTS
NWSA
CODE
NO.
4579

~&.a~
L~P
LLP
~ ~
S.
I
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranties and is
ex
clusive with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller
Electric
Mfg.
Co., Apple-
I.
Arc
welders,
power
sources,
and
components
. . .
I
year
ton,
Wisconsin
warrants to
Customer that all
new
and
unused
2.
Original
main
power
rectifiers 3
years
~j
Equipment
furnished
by
Miller
is
free from defect
in
workman-
(Labor

I
year
only)
ship
and
material
as
of the time and
place
of
delivery by
Miller.
3.
All
welding
guns
and
feeder/guns
90
(lays
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items manufactured
by
others. Such
engines,
4.
All
other
Millermatic Feeders
I
year
trade
accessories and
other
items
are
sold
subject
to
the
warran-
provided
that the
user
so
notifies Miller
in
writing
within
thirty
ties of
their
respective
manufacturers,
if
any.
At
the
present
time,
(30)
days
of
the
date of
such failure.
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL-
200 is limited to
six months
and
on
all
other
engines
to
one
year.
5.
Replacement
or
repair
parts
exclusive
of
labor
. .
60
days
MILLER
warranty
does
not
apply
to
components
having
ANY
EXPRESS
WARRANTY NOT
PROVIDED HEREIN
normal useful
life
of less
than
one
(I)
year,
such
as
spot
welder
AND ANY
IMPLIED
WARRANTY,
GUARANTY OR
REP-
~
p
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
RESENTATION AS
TO
PERFORMANCE,
AND
ANY
come
in
contact
with
the
welding
wire
including
nozzles and
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
nozzle insulators where
failure does
not
result from defect
in
FOR
THIS
PROVISION,
MIGHT ARISE
BY
IMPLICA
workmanship
or
material.
TION,
OPERATION OF
LAW,
CUSTOM
OF
TRADE
OR
In
the
case
of
Millers breach of
warranty
or
any
other
duty
COURSE OF
DEALING,
INCLUDING
ANY
IMPLIED
with
respect
to
the
quality
of
any
goods,
the exclusive
remedies
WARRANTY
OF MERCHANTABILITY OR
OF FITNESS
therefor
shall
be,
at
Millers
optIon,
(1)
repair
or
(2)
replace-
FOR PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
ment
or,
where
authorized
in
writing by
Miller
in
appropriate
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
cases,
(3)
the
reasonable cost
of
repair
or
replacement
at
an
EXCLUDED
AND
DISCLAIMED
BY MILLER.
authorized
Miller
service station
or
(4)
payment
of
or
credit
for
EXCEPT
AS
EXPRESSLY PROVIDED BY
MILLER
IN
the
purchase
price
(less
reasonable
depreciation
based
upon
WRITING,
MILLER
PRODUCTS
ARE INTENDED
FOR
actual
use)
upon
return
of the
goods
at
Customers
risk and
CX~
ULTIMATE
PURCHASE BY
COMMERCIAL/INDUS
pense.
Upon
receipt
of notice of
apparent
defect
or
failure,
TRIAL
USERS
AND FOR OPERATION
BY
PERSONS
Miller shall instruct the
claimant
on
the
warranty
claim
proce-
TRAINED
AND
EXPERIENCED
IN THE
USE AND
dures
to
be
followed.
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
FOR
CONSUMERS OR
CONSUMER
USE.
MILLER
nal
users
warranty
claims
on
warranted
Equipment
in the
event
WARRANTIES DO NOT
EXTEND
TO,
AND NO RE-
of
failure
resulting
from
a
defect
within
the
following
periods
SELLER
IS
AUTHORIZED TO
EXTEND
MILLERS
WAR
(
from the
date
of
delivery
of
Equipment
to
the
original
user:
RANTIES
TO,
ANY
CONSUMER.
~b
~
...~i, ~
~
~
~
~
~

ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet lists
exceptions
to
data
appearing
later
in
this manual.
flLE
COPY
RETUG~N
10
~LDE~
Item
Part
No.
Listed
No. in Parts List
28
052084
28
052085
BE
SURE TO
PROVIDE
Replaced
With
Part
No.
Description
Quantity
081
580
LINER,
monocoil
0.230
OD
x
.030
-
1/8
wire
x
lift
or
1
081
581
LINER,
moriocoil
0.230
OD
x
.030
-
1/8
wire
x
16
ft
1
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1515
Page
A
1
~I~I
r~~

SECTION
1
-
INTRODUCTION
Rating:
60%
Duty
Cycle
Wire
Diameter
Cooling
Method
Cable
Length
Net
Weight
Ship
Weight
250
Amperes
1/16
and
5/64
A
ir
icr
7lbs.4oz.
(3.29
kilos)
9lbs.4oz.
(4.20
kilos)
15
9lbs.Boz.
(4.31 kilos)
11
lbs.8oz.
)5.22
kilos)
400
Amperes
i/16,5/64,
and
3/32
Air
10
9 lbs.
(4.08
kilos)
ii
lbs.
)5.00
kilos)
15
11
lbs.
(4.99
kilos)
13
lbs.
)5.90
kilos)
Figure
1-1.
Specifications
1-1.
GENERAL
This
manual has
been
prepared
especially
for
use
in
familiar
izing
personnel
with the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment,
All
informa
__________________
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1-2.
RECEIVING-HANDLING
Prior
to
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
or
damage
that
may
have occurred in
transit
must
be
filed
by
the
purchaser
with
the carrier.
A
copy
of the bill of
lading
and
freight
bill
will be
furnished
by
the carrier
on
request
if
occasion
to
file
claim arises,
When
requesting
information
concerning
this
equipment,
it
is
essential that
Model
Description
and/or
Stock Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
___________
This
gun
is
designed
specifically
for
use
with the
self-shielding
Flux-Cored Arc
)FCAW)
Welding process
using
self-shielding
flux-cored
electrode.
The
gun
may
be
used for either
DC
straight
or
DC
reverse
polarity
applications.
All
necessary
components
for
the
specific
wire
size
ordered
are
shipped
with the
gun.
The
Contact
tube
is
the
only
component
that
needs
to
be
changed
when
a
wire
size
change
is
desired.
_____________
SECTION
2
-
INSTALLATION
2-1.
INSTALLATION
OF
MONOCOIL
LINER
1.
Lay
gun
cable
out
straight.
2.
Insert
monocoil
liner
fully
into
casing;
push
until
it
seats
firmly against
wire
straightener
(in
head tube
behind
contact
tube;
see
Parts
List
for
view).
3.
Tighten
set
screw
in head
tube
(via
clearance
hole
on
top
of
handle) and
in
cable
Connector. Do
not
overtighten.
4.
If
the
monocoil liner
protrudes
from
the
cable
connector
)feeder
end),
cut
the
liner
off
flush
with
the
end of
the
cable
connector.
2-2.
INSTALLATION OF
GUN
TRIGGER
SWITCH
PLUG

1. Make
connections
from the
gun
trigger
switch cord
to
the
plug
for the
control/feeder as
follows:
A.
MM
plug:
Attach
the
two
wires
to
the
two
terminals
on
the
plug;
tighten
screws;
slide
insulator
onto
plug.
B.
LN-7
and
LN-8: Slide
the
cable
clamp
(strain
relief)
onto
the
cord;
solder the
two wires
to
pins
A
and
Con
the
five-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
1-4.
SAFETY
The
following
definitions
apply
to
CAUTION,
IMPORTANT.
and
NOTE
blocks
found
throughout
this
manual:
1L~Il.J~IIuIIJ
I
Under
this
heading,
installation,
ope
rating,
and
main-
1
tenance
procedures
or
practices
will be found
that
ii
not
carefully
followed
may
create
a
hazard
to
per
sonnel.
r~TA~1
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result in
damage
to
equip
ment.
NOTE
1
I
I
I
Under this
heading,
explanatory
statements
will
be
found that
need
special emphasis
to
nhtain
the
most
efficient
operation
of the
equipment
ci
C.
LN-22:
Slide
the cable
clamp
(strain
relief)
Onto
the
cord;
solder
the
two
wires
to
pins
A
and
C
on
the
three-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
D. AA
2900:
Slide
the cable
clamp
(strain
relief)
onto the
cord;
solder the
two
wires
to
pins
A
and
D
on
the
four-pin
plug;
secure
clamp
to
plug
body;
tighten
screws.
2. When
the
connections
have been
properly made,
the
plug
is
ready
to
be attached
to
the
control/feeder
gun
switch
receptacle.
I
Prior
to
installing
the
gun,
ensure
that the
control/
feeder and
welding
power
source are
both
completely
disconnected
from
their
respective
input
electrical
power
supplies.
1
I
2-3.
GUN
TO
CONTROL/FEEDER
CONNECTIONS
1. Slide
one
end
of the
interconnecting power
cable
onto
the
threads
on
end
of
cable
connector,
where
applicable.
OM-1515
Page
1

2.
Rotate
outlet
guide
onto
cable
connector;
tighten
outlet
guide.
3.
Loosen
the
outlet
guide securing
screw
on
the drive
assembly
of
the
control/feeder.
4.
Insert the
outlet
guide
from
the
gun
cable
all
the
way
into
the outlet
guide
hole
on
the
drive
assembly
of the
control/feeder.
5.
Tighten
the
outlet
guide securing
screw.
6.
Connect
the
plug
installed
in
Section
2-2
to
the
gun
switch
receptacle
on
the
control/feeder.
7. Connect
the
remaining
end
of
the
interconnecting
power
cable
to
the
weld cable terminal
on
the
control/feeder,
where
applicable.
2-4.
CHANGING
WIRE
SIZE
The
contact
tube in
the
gun
is the
only
component
in
the
gun
and
gun
cable
assembly
that
needs
to
be
changed
to
accommodate
a
different
wire size.
The
contact
tube
is threaded.
To
remove,
rotate
in
a
counterclockwise
direction;
to
install,
rotate
in
a
clockwise
direction.
2-5. NOZZLE
A nozzle (1-3/4)
is
recommended for normal
applications.
If
longer
stick
out
of the
electrode
is
desired,
a
longer
nozzle
(2-3/8)
is
available
but must be
ordered
(see
Parts
List).
Should
very
close
work
be done
where
the
nozzle
is
not
desired,
a
thread
protector
is
available
for
use
when
the
nozzle is
removed
(see
Parts
List).
SECTION
3
-
MAINTENANCE
a.
Lay
cable
out
straight.
b.
Insert
monocoil
liner
fully
into
casing;
push
until it
seats
firmly
against
wire
straightener
(in
head
tube
behind
contact
tube;
see
Parts List for
view).
c.
Tighten
set
screw
in
head
tube and
in
cable
connector.
Do
not
overtighten.
d. If
a
new
monocoil
liner
has been
installed,
cut
the
liner
off
flush with the
feeder
end
of the
cable
connector.
e.
Reinstall
the
interconnecting
power
cable,
where
applicable.
f.
Reinstall
the outlet
guide.
3-2.
INSPECTION
AND
UPKEEP
Usage
and
conditions
will
determine
the
frequency
and
type
of
maintenance
required.
1.
Inspect
gun
for
broken
areas,
cracks,
and
loose
parts;
tighten,
repair,
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
or
foreign
matter
which
may
accumulate
around
the
nozzle
orifice.
3.
Repair
or
replace
cables
as
required; give
particular
attention
to
frayed
and
cracked
insulation
and
areas
where the
cables enter
equipment.
4.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cables.
r
I
S
L!1
Ensure
that
the
welding
power
source
is
completely
shut
down
and
that
power
is removed from
the
control/feeder
prior
to
performing any
maintenance
procedures.
3-1.
CLEANING
MONOCOIL LINER
Periodically,
depending
on
usage
and
conditions,
it
will
be
necessary
to
clean the
monocoil
liner
and
casing
to
remove
any
metal
chips
and
dirt that
may
have
accumulated.
To
clean,
proceed
as
follov~s:
-
1. Remove monocoil
liner
as
follows;
a.
Remove
outlet
guide
from
cable
connector.
b.
Remove
interconnecting
power
cable
from
cable
con
nector,
where
applicable.
c.
Remove
set
screw
from
cable
connector
and
from
head
tube
(via
clearance
hole
on
sop
of
handle).
d.
Lay
cable
out
straight,
and
pull
monocoil
liner
out
from
feeder
end.
2.
Blow
monocoil
liner
out
with
clean,
dry,
compressed
air.
3.
Blow
casing
out
in
same manner.
4.
Reinstall
monocoil
liner
as
follows;
Page
2

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

31
Figure
A

Complete
Assembly
TC-052
230
p
10
1 2 3
4
5 67
30
13
23
24
29
28
OM-1515
Page
1

Quantity
Item
Factory
Model
No. Part No.
Description
GL-25
GL-40
Figure
A
Complete
Assembly
1
601 957
SCREW,
cap
-
steel
hex
hd
1/4-20
x 1-1/2
11
2 052 066
HANDLE,
gun
-
left
hand
1
1
3
076 762
PIN,
spring
-
compression
2
2
4
000
369
SWITCH,
limit 10
amp
125/250
volts
ac
SPDT
1
1
5
052064
TRJGGER,gun
1
1
6
052
884
SCREW,
set
-
steel socket
hd
10-32
x
1/4 1
1
7
052 072
TUBE,
head
(8
inch)
1
1
8
052
074
INSERT,
straightener
-
wire
11
9
052 098
SCREW,
set
-
steel hollow
3/8-16 x
3/16
1
1
10
052
059
PROTECTOR,
thread
or
1
1
10
052 078
NOZZLE,
screw
1-3/4
or
1
1
10
052
075
NOZZLE,
screw
2-3/8
1
1
11
009709
TUBE,contact
1/l6wireor
1
1
11
052 055
TUBE,
contact 5/64
wire
or
1
1
11
008
926
TUBE,
contact
3/32
wire
1
12
052060
SHIELD,hand
1
1
13
052
095
SCREW,
set
-
steel socket hd
5/16-18
x
1/2
1
1
14
601 856
NUT,
weld
5/16-18
1
1
15
602
207
WASHER,
lock
-
steel
split
1/4
1
1
16
601 865
NUT,
steel
-
hex
full
1/4-20
2
2
17
052068
HANDLE,gun-right
hand
11
18
052088
CABLE/CONDUIT.
lOft
or
1
18
052089
CABLE/CONDUIT,
l5ft
1
18 052 090
CABLE/CONDUIT,
10 ft
or
1
18
052091 CABLE/CONDUIT,l5ft
1
19
053
076
CLAMP,
hose
1 inch
clamp
dia
1
1
20
005
177
STRAIN RELIEF
1
1
052
083
TUBING,
neoprene
5/8
ID
x
3/32
waIl
x
6
1
21
052
063
CONNECTOR,
cable
-
gun
1
1
22
052
883
SCREW,
set
-
steel socket
hd
10-32
x
3/8
1
1
23
052
092
CABLE,
connecting
-
power
(MM-30
Series
only)
1 1
24
052
058
GUIDE,
wire
-
outlet
1/16
-
3/32
(MM-30
Series)
or
1
1
24
052056
ADAPTER,gun/feeder
1/16-3/32
(2900)
or
11
24
052 057
ADAPTER,
gun/feeder
1/16
-
5/64
(LN-22)
or
1
1
24
052 158
ADAPTER,
gun/feeder
1/16
-
3/32
(LN-8)
1 1
25
604
523
CAP,
twist
lock
-
midget
2P2W
11
25
073
329
PLUG,
4
pin
97-3106A-18-4P
(2900)
1
1
073
331
CLAMP,
cable
(2900)
1
1
25
052236
PLUG,3pinMS-3106A-14S-1P(LN-22)
1
1
039 828
STRAIN
RELIEF,
receptacle/plug
(LN-22)
1
1
25
052237
PLUG,5
pin
MS-3106A-18-11P
(LN-8)
11
073 332
CLAMP,
cable
(LN-8)
1
1
26
052086
CORD,trigger
11 ftor
1
1
26
052
087
CORD,
trigger
16 ft 1
1
27
053132
STRAIN
RELIEF,cable
1
1
28
052084
LINER,monocoil
1/16-3/32wirex
11 ftor 1
1
28
052085
LINER,monocoil
1/16-3/32wirex
16ft
1 1
29
052 071
CLAMP,
head
tube 11
30
057
544
SPRING,
compression
1 1
31
052
919
SCREW,
machine
-
steel
round hd
1/4-20
x
7/8 1 1
Parts
For
Optional
Equipment
7
052 419
TUBE,
head
(12
inches)
28
052
837
LINER,
monocoil
1/1 6-3/32
wire
x
16
ft.
4
inches
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1515
Page
2

-~-Th