Miller GA-5OGL User manual

Millerfi
August
1990
FORM:
OM-1532B
Effective
With
Style
No.
KA-27
MODEL::
GA-5OGL
OWNERS
MANUAL
4.
IMPORTANT:
Read and understand the entire
contents
of both this manual
and the
power
source
manual used with this
unit,
with
special emphasis
on
the
safety
material
throughout
both
manuals,
before
installing, operating,
or
maintaining
this
equipment.
This
unit and
these instructions
are
for
use
only
by
persons
trained and
experienced
In
the
safe
operation
of
welding equip
ment.
Do
not
allow untrained
persons
to
install,
operate,
or
maintain this
unit.
Contact
your
distributor
if
you
do
not
fully
understand these instructions.
MILLER
ELECTRIC
Mfg.
A Miller
Group
Ltd.,
Company
a
P.O. Box
1079
Appleton,
WI 54912
USA
Tel.
414-734-9821
B-045
t14
PRINTED
IN
U.S.A.

I
J
LIMITED WARRANTY
EFFECTIVE:
AUGUST
6,
1990
L
This
warranty
supersedes
all
previous
MILLER
warranties and is
exclusive with
no
other
guaTantees
or
warranties
expressed
or
implied.
IF
LIMITED
WARRANTY

Subject
to
the
terms
and
conditions
hereof,
MILLER
Electric
Mfg.
Co.
Appleton,
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free from
defect
in
workmanship
and
material
as
of the time and
place
of
delivery
by
MILLER.
No
warranty
is
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items manufactured
by
others.
Such
engines,
trade accessories and
other items
are
sold
subject
to
the
warranties of their
respective
manufacturers,
if
any.
All
engines
are
warrantied
by
their manufacturer for
two
years
from date
of
original purchase,
except
Deutz
engines
which
have
a one
year,
2000 hour
warranty.
Except
as
specified
below,
MILLERs
warranty
does
not
apply
to
components having
normal
useful life of less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with the
welding
wire
including
nozzles and
nozzle
insulators where failure does
not
result
from
defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in the
event
of failure
resulting
from
a
defect
within the
following
periods
from
the
date of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load banks
1
year
3.
Original
main
power
rectifiers 3
years
(labor

1
year
only)
4.
All
welding
guns,
feeder/guns
and torches
...
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive of labor 60
days
7.
Batteries
6
months
provided
that
MILLER is notified
in
writing
within
thirty
(30) days
of the date of such failure.
As
a
matter
of
general
policy only,
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERs
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the exclusive remedies
therefore shall be.
at
MILLERs
option (1) repair
or
(2)
replace
ment
or,
where
authorized
in
writing
by
MILLER in
appropriate
cases, (3)
the reasonable
cost
of
repair
or
replacement
at
an
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price (less
reasonable
depreciation
based
upon
actual
use)
upon
return
of the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
F.O.B.,
Factory
at
Appleton,
Wisconsin.
or
FOB.
at
a
MILLER
authorized service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon receipt
of
notice of
apparent
defect
or
failure,
MILLER
shall
instruct the
claimant
on
the
warranty
claim
procedures
to
be followed.
ANY
EXPRESS
WARRANTY NOT PROVIDED HEREIN
AND ANY
IMPLIED
WARRANTY,
GUARANTY OR REPRE
SENTATION
AS TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH OF CONTRACT
WHICH,
BUT FOR THIS
PROVISION,
MIGHT ARISE BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF TRADE OR COURSE OF
DEALING,
INCLUDING
ANY IMPLIED WARRANTY
OF
MERCHAN
TABILITY
OR OF
F!TNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY AND ALL
EQUIPMENT
FURNISHED
BY
MILLER IS EXCLUDED
AND
DISCLAIMED
BY MILLER.
EXCEPT AS
EXPRESSLY PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE INTENDED
FOR
ULTIMATE PURCHASE BY
COMMERCIAL/INDUSTRIAL
USERS
AND FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND MAINTENANCE
OF
WELDING EQUIPMENT
AND
NOT FOR CONSUMERS OR
CONSUMER USE.
MILLERS
WARRANTIES
DO NOT
EXTEND
TO,
AND NO RESELLER IS AUTHORIZED
TO
EXTEND
MILLERS WARRANTIES
TO,
ANY
CONSUMER.
I

March
16,
1992
FORM:
OM-1532
I
ERRATA SHEET
___________________
-
After
this
manual
was
printed,
refinements
in
equipment design
occurred.
This
sheet
lists
exceptions
to-data
appearing
later
in
this manual.
AMENDMENT
TO
SECTION
5
MAINTENANCE
Add the
following
IMPORTANT
block
at
the
beginning
of
Section
5-3.
CHANGING
WIRE
SIZES
IMPORTANT: Guns
shipped
for
use
with
1/16, .0687.072,
or
5/64
in.
(1.6,
1.8,
or2.
0
mm)
wire do
not
have
a
stub
lin~
r
in
the
head tube. When
changing
to
a
larger
wire
size,
a
stub
liner
must
be inserted into
the
head tube.
Guns
shipped
for
use
with
3/32,
7/64,
or
1/8
in.
(2.4,
2.8,
or
3.2
mm)
wire have
a
stub liner
in
the head
tube.
When
changing
to
a
smaller
wire
size,
the stub
liner is
removed
and the
monocoll
liner
goes
through
the head tube.
AMENDMENT
TO SECTION
8
PARTS LIST
Amend Parts
List
as
follows:
Part
Replaced
No.
With
Description
Quantity
7-
Added
....
008
931
.
LINER,
monocoil
3/32-1/8
wire
x
7.250
1
7-26
...
008 759
....
088 759
.
LINER,
monocoil
3/32-1/8
wire
x
l5ft
1
~First
digit
represents
page
no

digits
following
dash
represent
item
no.
BE
SURE TO 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
to
record
the
Model
Designa
age
that
may
have
occurred
during shipment.
File
any
tion and
Serial
or
Style
Number
of
your
unit.
The infor
claims for
loss
or
damage
with the
delivering
carrier.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from the
distributor
and/or the
equipment
manufactur-
Model
_________________________________
ers
Transportation
Department.
Serial
or
Style
No.
-
When
requesting
information
about
this
equipment,
al
ways
provide
the Model
Description
and
Serial
or
Style
Date
of
Purchase
_____________________
Number.
TABLE
OF CONTENTS
Section
No.
Page
No.
SECTION 1

SAFETY PRECAUTIONS
AND
SIGNAL
WORDS
1-1
General
Information And
Safety
1
1-2
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2
SPECIFICATIONS
2-1.
Duty
Cycle
1
2-2.
Description
1
SECTION
3INSTALLATION
3-1.
Gun/Feeder
Connector
Installation
3
3-2.
Nozzle
(Optional)
3
3-3.
Installation Of
Trigger
Switch
(Optional)
3
SECTION
4SEQUENCE
OF
OPERATION
4-1.
Flux
Cored
And
Manual
Submerged
Arc
Welding
3
4-2.
Shutting
Down
4
SECTION
5
MAINTENANCE
5-1.
Inspection
And
Upkeep
4
5-2.
Contact
Tube
Replacement
4
5-3.
Changing
Wire
Sizes
5
SECTION
6
PARTS LIST
Figure
6-1
Exploded
View
Of
Gun
(Gun
With
1/16
Wire
Illustrated)
6
LIST OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1

SECTION
1
-
SAFETY PRECAUTIONS
AND SIGNAL WORDS
1-1
GENERAL INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this manual and
on
various la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which should
be
read, understood,
and
followed
forthe safe and effective
use
of this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and trouble
shooting
of.
arc
welding equipment
requires
practices
and
procedures
which
ensure
personal safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by qualified
per
Sons
in
accordance with this
manual and
all
applicable
codes such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section 1

Safety
Rules For
Operation
Of
Arc
Weld
ing
Power
Source.
1-2
SAFETY
ALERT
SYMBOL
AND
SIGNI
WORDS
The
following
safety
alert
symbol
and
signal
words
a
used
throughout
this
manual
to
call attention
to
and
ide
tify
different levels of hazard and
special
instructions
a
This
safety
alert
symbol
is used
with the
sigr
words
WARNING
and
CAUTION
to
call
atte
tion
to
the
safety
statements.
4A
WARNING
statements
identify procedures
practices
which
must
be followed
to
avoid
se
ous
personal injury
or
loss of life.
4A
CAUTION
statements
identify
procedures
practices
which
must
be followed
to
avoid
mir
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructiohs
necessary
for
the
most
efficient
operation
of
this
equ
-
ment.
SECTION
2-
SPECIFICATIONS
Table
2-1.
SpecificatIons
2-1.
DUTY CYCLE
The
duty
cycle
of
awelding
gun
is
the
percentage
of
a
ten
minute
period
that
a
gun
can
be
operated
at
a
given
out
put.
This
gun
is
rated
at
100
percent
duty
cycle.
This
means
that
the
gun
can
be
operated
at
rated
load
con
tinuously
with
the
self-shielding
Flux Cored
Arc
Welding
proces
The
gun
is
shipped
with
the
necessary
components
the
specificwire
size
ordered.
Through
minorchanges
parts
the
gun
may
be used with
1/16,
.068/.072,
5/6
3/32, 7/64,
or
1/8
in.
(1.6,
1.8,
2.0, 2.4,
2.8,
or
3.2
mr
flux
cored
wire. The
GA-5OGL
is
designed
for
semiaut
matic
scratch
start
open
arc
welding.
The
alpha-numeric
designation
refers
to
the
followin
G-gun
A
-
air cooled
50
-
ampere
rating:
500
ampere
GL
-
gasless
L
1
31
1
)r
Rating:
100%
I
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
m
15ft.
4.6m
Air
Air
12
lbs.
l4lbs.
5.4
kg
6.4kg
14
lbs.
6.4
kg
l6lbs.
7.3kg
4A
CAUTION:
EXCEEDING
DUTY CYCLE
RAT
ING
will
damage
the
welding
gun.

Do
not
exceed rated
duty
cycle.
2-2.
DESCRIPTION
This
gun
is
designed
specifically
for
use
in
conjunction
S.
in
4,
OM-1532
Page
1

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
Centering
Sleeve
Setscrew
Gun
Handle
Liner
Insulator
OM-1532
Page
2

a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not touch
live
electrical
parts.

Shut
down
wire
feeder
and
welding
power
source
and
disconnect
input
power
employing
locko
ut/tagging
procedures
before
inspecting
or
installing
gun.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
posi
tion,
removing
fuses from fuse
box,
or
shutting
off and
red-tagging
circuit
breaker
or
other
dis
connecting
device.
3-1.
GUN/FEEDER CONNECTOR
INSTALLATION
(Figure
3-1)
Proceed
as
follows
to
install the
gun/feeder
connector
into
the
drive
assembly
on
the wire
feeder.
IMPORTANT:
The outlet
guide
is
pro
videdas
part
of
the
gun
assembly.
1.
Loosen
the
gun/feeder
connector
securing
knob
on
the
wire drive
assembly.
IMPORTANT:
The outlet
guide
should
be
positioned
as
close
as
possible
to
the
drive
rolls
without
touching
them.
This
gives
the
wire maximum
column
stren~
thus
ellminating
waves.
2. Insert
the
gun/feeder
connector
into
the wire dri
assembly.
3.
Tighten
the
gun/feeder
connector
securing
knob.
3-2.
NOflLE
(Optional)
A
1-3/4
in.
(44.5
mm)
nozzle is recommended
for
norrr
application.
It
longer
stick out
of the
electrode is desire
a
2-3/8
in.
(60 mm)
nozzle
is available.
The
gun
shipped
with
a
thread
protector
which
should
be
us
when
a
nozzle
is
not.
3-3.
INSTALLATION
OF
TRIGGER
SWITCH
(0
tlonal)
IMPORTANT: The
installation of
trigger
switch
ada~
the
GA-5OGL
gun
for
use
with
any
feeder
requiring
switch-type starting
system.
1.
Position the
triggerswitch
on
the
gun
handle and
s
cure
with
supplied
clamp.
2.
Insert
the
amphenol
gun
switch
plug
into the
switc~h
control
receptacle
on
the wire
feeder. Rotate
the
plug
collar
clockwise to
lock
plug
in
receptacle.
SECTION
4
SEQUENCE OF
OPERATION
4A
WARNING: ELECTRIC SHOCK
can
kill;
MOVING
PARTS
can
cause
serIous
Injury;
IMPROPER AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
internal
parts.

Do
not touch
live
electrical
parts.

Keep
away
from
moving
parts.

Keep
all
covers
and
panels
in
place
while
operating.
Warranty
is
void
if
the
wire
feeder
is
operated
with
any
portion
of
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
of
the
fumes.

Ventilate
to
keep
from
beathing
fumes
and
gases.

If
ventilation
is
inadequate,
use
approved
breathing
device.
WELDING
WIRE
can
cause
puncture
wounds.

Do
not
point
gun
to
ward
any
part
of
the
body,
any
conductive
surface,
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire and burns.

Watch for
fire.

Keep
a
fire
extinguisher
nearby,
and know
how
to
use
it.

Do
not
use
near
flammable
material.

Allow
work
and
equipment
to
cool be
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
1
-
Safety
Rules For
Operation
Arc
Welding
Power
Source
in
the
welding
pow
source
Owners Manual
for basic
welding
safe
information.
4-1.
FLUX CORED
AND
MANUAL
SUBMERGE
ARC WELDING
1.
Ensure
that
proper
electrical connections
hay
been made
to
the
welding
power
source
and th
wire
feeder.
2.
Ensure
that the
welding
wire
has
been
properi
threaded
and that
correct
initial tension
has
been
s~
on
the drive
rolls
(refer
to
the
wire
feeder
Owner:
Manual).
3.
Place
control(s)
on
wire feeder
in
the
desired
pos
tion
for
the
welding
setup.
OM-1532
Page
3
f/i
e
al
:1,
is
d
ts
a
S
g
)f
y
)
e
e
y
S

4.
Place the controls
on
the
welding
power
source
in
the
desired
position
for
the
welding
setup
(refer
to
welding
power
source
Owners
Manual).
5.
Energize
the
welding
power
source
and
wire
feeder
(refer
to
the
respective
Owners
Manuals).
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Shut
down
welding
power
source
and wire
feeder,
and
disconnect
gun
before
hand/mg
or
rep/acing
any gun
parts.

When
not
in
use,
store
the
gun
in
insulated
holder
so
wire
cannot
be
touched
or
make
contact
with
metal surfaces.

Wear
dry
insulating
gloves
and
use
insu
lated tools
when
cutting
wire.
The
welding
wire
andailmetal
parts
in
contact
with
it
are
electrically
hot whenever the
wire
feeder
is connected
to
an
energized
welding
power
supply.
6.
Actuate
jog
switch
or
optional
Trigger
Switch,
if
ap
plicable,
to
run
the wire
out
beyond
the end
of the
contact
tube.
Cut the wire
off
so
it sticks
out
approxi
mately
1/2to 3/4
in.
(13
to
19
mm)
from
the
nozzle..
7.
Hold end
of nozzle
approximately
1
in.
(25 mm)
from
workpiece.
8.
Touch
welding
wire
to
workpiece
or
press
optional
Trigger
Switch,
if
applicable,
to start
wire
feed;
an
arc
will
be established.
If
wire
slippage
is
noticed,
tighten
drive
roll
pressure
adjustment
1/4
turn
at
a
time
until
slippage
stops.
Do
not
overtighten.
9.
After
the controls
on
the
welding
power
source
and
wire
feeder
are
adjusted
for
normal
operation, they
will
function
automatically
whenever
the
welding
wire
touches the
workpiece
or
the
optional
Trigger
Switch
is
depressed.
Removing welding
wire from
workpiece
or
releasing
the
Trigger
Switch,
if
applica
ble,
will
break the
arc
and
cause
wire feeder
to
stop.
4-2.
SHUTTING DOWN
1.
Stop
welding
(remove
wire
from
workpiece).
2.
Turn off
welding
power
source
and
wire feeder.
SECTION
5
MAINTENANCE
a
WARNING:
ELECTRIC SHOCK
can
kill;
MOVING
PARTS
can cause
serious
injury;
WELDING
WIRE
can cause
puncture
wounds;
HOT SURFACES
can cause severe
burns.

Do
not
touch live electrical
parts.

Shut
down
welding
power
source
and wire
feeder
before
working
on
gun.

When
not
in
use,
store
the
gun
in
insulated
holder
so
wire
cannot
be touched
or
make
con
tact
with
metal
surfaces.

Disconnect
gun
from
wire
feeder
before in
specting, maintaining,
or
servicing.

Allow
a
cooling
period
before
servicing.
5-1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance
required.
1.
Inspect
gun
for broken
area,
cracks
and loose
parts;
tighten,
repair,
and
replace
as
required.
2.
Carefully
remove
any
weld
spatter
orforeign
matter
which
may
accumulate around the nozzle
orifice.
3.
Remove
any
accumulation
around the
Trigger
Switch,
if
applicable.
4.
Repair
or
replace
as
required
all
cables;
give
par
ticular attention
to
frayed
and cracked insulation and
areas
where it
enters
equipment.
5. 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.

Do
not
touch
live
electrical
parts.

Shut
down
welding
power
source
and wire
feeder
before
working
on
gun.

When
not
in
use,
store
the
gun
in
insulated
holder
so
wire
cannot
be touched
or
make
con
tact
with
metal surfaces.

Disconnect
gun
from wire feeder
before
in
specting, maintaining,
or
servicing.

Allow
a
cooling period
before
servicing.
1.
Remove nozzle.
2.
Cut
off
any
portion
of
the electrode wire
which
ex
tends
beyond
end of
contact
tube.
3.
Remove
contact
tube and
replace
with
new
contact
tube.
4.
Replace
nozzle and
resume
operation.
a
OM-1532
Page
4