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The following terms are
used interchangeably
throughout this manual:
MIG=GMAW

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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1-1.

Symbol Usage

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1-2.

Arc Welding Hazards

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1-3.

Additional Symbols for Installation, Operation, and Maintenance

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1-4.

Principal Safety Standards

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1-5.

EMF Information

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SECTION 1. CONSIGNES DE SECURITE − LIRE AVANT UTILISATION

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1.1

Signification des symboles

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1.2

Dangers relatifs au soudage à l’arc

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1.3

Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance

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1.4

Principales normes de sécurité

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1.5

Information sur les champs électromagnétiques

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SECTION 2 − SPECIFICATIONS

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2-1.

Specifications

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2-2.

Duty Cycle And Overheating

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2-3.

Volt-Ampere Curves

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SECTION 3 − INSTALLATION

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3-1.

Installing Welding Gun

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3-2.

Changing Polarity

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3-3.

Process/Polarity Table

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3-4.

Installing Gas Supply

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3-5.

Selecting A Location And Connecting Input Power For 120 VAC Model

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3-6.

Selecting A Location And Connecting Input Power For 230 VAC Model

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3-7.

Electrical Service Guide For 230 VAC Model

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3-8.

Installing Wire Spool And Adjusting Hub Tension

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3-9.

Threading Welding Wire

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SECTION 4 − OPERATION

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4-1.

Controls

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4-2.

Weld Parameters For 120 VAC Model

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4-3.

Weld Parameters For 230 VAC Model

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SECTION 5 − MAINTENANCE &TROUBLESHOOTING

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5-1.

Routine Maintenance

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5-2.

Overload Protection

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5-3.

Changing Drive Roll Or Wire Inlet Guide

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5-4.

Short Circuit Shutdown

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5-5.

Replacing Gun Contact Tip

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5-6.

Cleaning Or Replacing GA16C2 Gun Liner

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5-7.

Troubleshooting Table

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SECTION 6 − ELECTRICAL DIAGRAM

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SECTION 7 − MIG WELDING (GMAW) GUIDELINES

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7-1.

Typical MIG Process Connections

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7-2.

Typical MIG Process Control Settings

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7-3.

Holding And Positioning Welding Gun

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7-4.

Conditions That Affect Weld Bead Shape

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7-5.

Gun Movement During Welding

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7-6.

Poor Weld Bead Characteristics

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7-7.

Good Weld Bead Characteristics

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7-8.

Troubleshooting − Excessive Spatter

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7-9.

Troubleshooting − Porosity

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7-10. Troubleshooting − Excessive Penetration

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7-11. Troubleshooting − Lack Of Penetration

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7-12. Troubleshooting − Incomplete Fusion

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7-13. Troubleshooting − Burn-Through

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7-14. Troubleshooting − Waviness Of Bead

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7-15. Troubleshooting − Distortion

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7-16. Common MIG Shielding Gases

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SECTION 8 − PARTS LIST

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WARRANTY

OM-210089B

Содержание GA16C2

Страница 1: ...Processes OM 210 089B September1998 MW 135 MW 175 And GA16C2 Gun Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding ...

Страница 2: ......

Страница 3: ...r 230 VAC Model 16 3 8 Installing Wire Spool And Adjusting Hub Tension 16 3 9 Threading Welding Wire 17 SECTION 4 OPERATION 18 4 1 Controls 18 4 2 Weld Parameters For 120 VAC Model 19 4 3 Weld Parameters For 230 VAC Model 20 SECTION 5 MAINTENANCE TROUBLESHOOTING 21 5 1 Routine Maintenance 21 5 2 Overload Protection 21 5 3 Changing Drive Roll Or Wire Inlet Guide 22 5 4 Short Circuit Shutdown 22 5 5...

Страница 4: ......

Страница 5: ... is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conductor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do not drape cables ov...

Страница 6: ... welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off sla...

Страница 7: ...d maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area ...

Страница 8: ...s is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one ...

Страница 9: ...ne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre D En effectuant les raccordements d entrée fixer d abord le conducteur de mise à la terre approprié et contre vérifier les connexions D Vérifier fréquemment le cordon d alimentation pour voir s il n est pas endommagé ou dénudé remplacer le cordon immédiatement s il est endommagé un câble dén...

Страница 10: ...act D Porter des vêtements de protection dépourvus d huile tels que des gants en cuir une chemise en matériau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce ...

Страница 11: ... dispositifs de protection LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences D Le rayonnement haute frequence peut provoquer des interférences avec les équipements de ra dio navigation et de communication les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l install...

Страница 12: ...générales du document intitu lé Biological Effects of Power Frequency Electric Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Govern ment Printing Office mai 1989 publié par le Office of Technology Assessment du Congrès américain il existe maintenant d abon dantes données scientifiques compilées à la suite d expériences sur la cellule ou d études sur des animaux et des humains qui ...

Страница 13: ...m Wire Feed Speed Range At No Load Wire Type And Dia 023 030 in 0 6 0 8 mm 030 035 in 0 8 0 9 mm 160 870 IPM 4 1 22 5 m min CSA Rating B 230 VAC Model Rated Welding Output Amperage Range Maximum Open Circuit Voltage DC Amperes Input at Rated Load Output 230 V 50 60 Hz Single Phase KVA KW Weight W Gun Overall Dimensions 130 A 20 Volts DC 30 Duty Cycle At 60 Hz Input 20 Duty Cycle At 50 Hz Input 30 ...

Страница 14: ... fifteen minutes for unit to cool Reduce amperage or duty cycle before welding Y Exceeding duty cycle can damage unit or gun and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4 95 SA 802 090 SA 802 091 A 120 VAC Model B 230 VAC Model 3 Minutes Welding 7 Minutes Resting 30 dutycycle at 90 amps 3 Minutes Welding 7 Minutes Resting 30 dutycycle at 130 amps 60 Hz 20 duty cycl...

Страница 15: ...The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall be tween the curves shown ssb1 1 10 91 ST 802 082 ST 802 089 A 120 VAC Model B 230 VAC Model ...

Страница 16: ...1 2 3 3 2 Changing Polarity 1 Lead Connections For Direct Current Electrode Positive DCEP 2 Lead Connections For Direct Current Electrode Negative DCEN Always read and follow wire manufacturer s recommended po larity and see Section 3 3 Close door 1 Ref ST 802 024 2 3 3 Process Polarity Table Process Polarity Cable Connections Process Polarity Cable To Gun Cable To Work GMAW Soild wire with shield...

Страница 17: ...ertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect customer supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire man ufacturer s recommended flow rate 8 CO2 Adapter Customer Sup plied 9 O Ring Customer Supplied Install a...

Страница 18: ...idual branch circuit protected by time delay fuses or circuit breaker is required 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 Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 2 1 3 18 in 460 mm 18 in 460 mm ST 802 178 ...

Страница 19: ...o receptacle 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 ssb2 2 1 94 Ref ST 802 179 1 18 in 457 mm of space for airflow L1 L2 L1 L2 2 230 VAC 1 Y Always connect grounding conductor first GND PE 4 3 Y Do not move or operate unit where it could tip ...

Страница 20: ...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 Installing Wire Spool And Adjusting Hub Tension S 0499 15 16 in Standard Wire Spool 8 in 1 Lb Wire Spool 4 in Turn wingnut When a slight force is needed to turn spool tension is set Tools Needed Adjusting Hub Tension Install spool so w...

Страница 21: ...2 mm Tighten Remove gun nozzle and contact tip Open pressure assembly Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Hold wire tightly to keep it from unraveling Ref ST 802 081 Ref ST 205 837 WOOD Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close and latch door Press gun trigger until wire ...

Страница 22: ...ion fan runs but there is no weld output 3 Wire Speed Control Use control to select a wire feed speed As Voltage switch setting increases wire speed range also increases see weld setting label in welding power source or Sections 4 2 or 4 3 as applicable 4 Power Switch Ref ST 205 387 2 1 3 MAX STEEL THICKNESS MATERIAL 18 24 GA 022 047 062 16 GA 125 11 GA 1 0 WIRE FEED SPEED 2 3 4 WELD VOLTS 10 9 8 ...

Страница 23: ...hes Door Hinge Bailers Combines Bumpers Brackets Grain Wagons Wheelbarrows Garage Door Trailers Trailer Frames Fencing Lawnmower Decks Work Auto Door Brackets Galvanized Roofing Trailer Sides Garage Door Tracks Tailpipes Motorcycles Decks Basketball Posts Wheelbarrows Lawnmower Tailpipes Bicycles Wagons Tricycles Duct Lawnmower Handles Auto Body THICKNESS Cubic Ft Hr Inches STICKOUT WIRE SPEED WIR...

Страница 24: ...CEP DCEP DCEP DCEN DCEN DCEN DCEN DCEN DCEN DCEN DCEP 1 2 2 1 2 2 2 1 1 3 3 3 2 2 4 4 4 3or4 3or4 3 2 1 9 6 7 4 5 5 5 4 5 5 4 5 6 7 7 8 4 5 5 6 4 5 4 5 5 5 6 7 5 5 5 4 5 3 4 4 5 5 5 4 5 5 4 5 4 5 5 5 4 5 5 4 5 5 5 1 4 1 4 1 4 5 16 5 16 5 16 5 16 1 2 1 2 5 16 3 8 3 8 1 2 1 2 1 2 1 2 1 2 1 2 3 4 3 8 3 8 1 2 Brackets Axles A Frames Farm Equipment Frames Basketball Rims and Brackets 3 16 to1 4 4 TRI M...

Страница 25: ...ce clean monthly Or 5 2 Overload Protection Ref ST 802 081 1 Circuit Breaker CB Circuit breaker CB protects wire feed motor from overload If circuit breaker opens wire stops feeding 2 Circuit Breaker CB1 CSA Model CB1 protects unit from overload If CB1 opens unit shuts down 3 Circuit Breaker CB2 CSA Model Circuit breaker CB2 protects wire feed motor from overload If circuit breaker opens wire stop...

Страница 26: ...e of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 3 9 NOTE when chang ing drive rolls make sure the woodruff key is on the motor shaft and not in the old drive roll 4 Drive Roll Securing Screw Secure drive roll with screw as shown Tools Needed 2 1 3 4 Ref ST 802 024 ST 802 139 5 4 Replacing Gun Contact Tip Ref ST 149 326 A Y Turn Off power before ...

Страница 27: ...stall 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 Install nozzle Remove nozzle contact tip and liner collet Remove liner Gun feeder connector Blow out gun casing 3 8 in 3 8 in 3 8 in Turn off welding power source wire feeder ...

Страница 28: ...ctions see Section 3 2 Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 4 1 Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts welding Adjust drive roll pressure see Section 3 9 Change to proper drive roll groove see Section 5 3 Readjust hub tension see Section 3 8 Repl...

Страница 29: ...OM 210 089 Page 25 SECTION 6 ELECTRICAL DIAGRAM ST 205 400 53 Figure 6 1 Circuit Diagram For 120 VAC Model ...

Страница 30: ...OM 210 089 Page 26 ST 210 011 B 53 17 Overload Feed Motor Figure 6 2 Circuit Diagram For 120 VAC CSA Model ...

Страница 31: ...OM 210 089 Page 27 ST 205 423 B 53 53 Figure 6 3 Circuit Diagram For 230 VAC Model ...

Страница 32: ...ections 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 Wire Feeder Power Source Workpiece Gun Regulator Flowmeter Gas Shielding Gas Work Clamp light mig 5 967 ST 801 909 ...

Страница 33: ...035 in 023 in 40 145 A 50 180 A 30 90 A 035 in Select Wire Speed Select Voltage Wire Recommendation 030 in 035 in 023 in 2 in per ampere 1 6 in per ampere 3 5 in per ampere Wire Speed 2 x 125 A 250 ipm 1 6 x 125 A 200 ipm 3 5 x 125 A 437 ipm Set voltage midway between high low voltage Low voltage wire stubs into work High voltage arc is unstable spatter 125 A based on 1 8 in Thickness to Amperage ...

Страница 34: ... 13 mm past end of nozzle and tip of wire is positioned correctly on seam NOTE 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 2 3 5 4 90 90 0 15 45 45 GROOVE WELDS FILLET WELDS End View Of Work Angle Side View Of Gun Angle End View Of Work Angle Side View Of Gun Angle 1 0 15 S 0421 A ...

Страница 35: ...ectrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage NOTE Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS STICKOUT FILLET WELD ELECTRODE EXTENSIONS STICKOUT Push Perpendicular Drag GUN TRAVEL SPEED Slow Normal Fast S 0634 ...

Страница 36: ...ement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 7 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 S 0053 A 7 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or la...

Страница 37: ... or liner 7 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hol...

Страница 38: ...of 0 to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed 7 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding w...

Страница 39: ...ses 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 Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Act...

Страница 40: ...he most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel Short Circuiting Stainless Steel Short Circuiting Aluminum Argon All Positions Argon 25 CO2 Flat Horizontal1 Fillet All Positions All Positions2 CO2 Flat Horizontal1 Fillet All Positions Tri Mix3 All Positions 1 Globular Transfer 2 Single Pass Welding Only 3 90 HE 7 1 2 AR...

Страница 41: ...OM 210 089 Page 37 Notes ...

Страница 42: ...OM 210 089 Page 38 SECTION 8 PARTS LIST Hardware is common and not available unless listed ST 802 066 Figure 8 1 Main Assembly ...

Страница 43: ...ssy 120 VAC model 1 24 184 735 GUIDE wire output 1 25 205 419 TRANSFORMER power assembly 230 VAC model 1 25 210 000 TRANSFORMER power assembly 120 VAC model 1 26 205 398A BRACKET mtg fan motor and heat sink 1 27 117 014 MOTOR fan 230 VAC model 1 27 111 931 MOTOR fan 120 VAC model 1 28 203 431 1 HANDLE lifting 1 29 203 601 1 SPRING handle mount 2 30 204 521 1 PANEL side gray 1 30 204 521 BA PANEL s...

Страница 44: ...BLE power assembly 120 VAC model 1 60 201 234 3 LEAD ground 6 1 61 205 424A LABEL door 230 VAC model 1 61 205 406A LABEL door 120 VAC model 1 405 548 LABEL ground screw not shown 1 62 406 636 LABEL moving parts 1 407 099 LABEL electric shock CSA model not shown 1 63 TRY 119 1 CONNECTOR strain relief 1 When ordering a component originally displaying a precautionary label the label should also be or...

Страница 45: ...1 9 M154 825 TIP contact 030 1 9 M154 824 TIP contact 035 1 10 110 794 TRIGGER SWITCH ASSEMBLY 1 11 110 792 CABLE 10ft 1 12 110 797 SLEEVE rubber 1 13 167 440 LINER monocoil 023 035 wire 10ft consisting of 1 14 110 784 COLLET liner 035 wire 1 15 079 974 O RING 1 2 ID x 062 2 ST 801 994 Hardware is common and not available unless listed 1 3 4 5 6 7 8 2 10 1 1 11 12 13 14 15 9 Figure 8 2 Complete As...

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