ESAB Air-Cooled SSG Series 300 AMP ELIMINATOR® Spool Gun User manual

Brand: ESAB

Model: Air-Cooled SSG Series 300 AMP ELIMINATOR® Spool Gun

Category: Welding System

Type: User manual

Issue Date: December 8, 2009

Manual No: 89200011 Revision: A

SAFETY AND OPERATING

INSTRUCTIONS

ELIMINATOR

SPOOL GUN

English

Français

Español

AIR-COOLED

SSG SERIES

300 AMP

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Tweco

product. We are proud to have

you as our customer and will strive to provide you with the best service

and reliability in the industry. This product is backed by our extensive

warranty and worldwide service network. To locate your nearest

distributor or service agency call 800-426-1888, or visit us on the web at

www.tweco.com.

This Manual has been designed to instruct you on the correct

installation and use of your Tweco

product. Your satisfaction with

this product and its safe operation is our ultimate concern. Therefore,

please take the time to read the entire manual, especially the Safety

Precautions. They will help you to avoid potential hazards that may

exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Tweco

is a Global Brand of Welding Products for Thermadyne

Industries Inc. We manufacture and supply to major welding industry

sectors worldwide, including: Manufacturing, Construction, Mining,

Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through market-

leading, dependable products that have stood the test of time. We

pride ourselves on technical innovation, competitive prices, excellent

delivery, superior customer service and technical support, together

with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced

products to achieve a safer working environment within the welding

industry.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices

before installing, operating, or servicing the equipment. While the information

contained in this Manual represents the Manufacturer’s judgment, the Manufacturer

assumes no liability for its use.

Eliminator Spool Gun

Safety and Operating Instructions

Instruction Guide Number 89200011

Published by:

Thermadyne

Industries, Inc.

2800 Airport Rd.

Denton, TX. 76207

(940) 566-2000

www.tweco.com

U.S. Customer Care: (800) 426-1888

International Customer Care: (940) 381-1212

Reproduction of this work, in whole or in part, without written permission of the publisher is

prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss

or damage caused by any error or omission in this Manual, whether such error results from

negligence, accident, or any other cause.

Publication Date: December 8, 2009

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

Table of Contents

SECTION 1: INTRODUCTION ..................................................................................1-1

1.01 How to Use this Manual ................................................................1-1

1.02 Receipt of Equipment ....................................................................1-1

1.03 Description ....................................................................................1-1

SECTION 2: SAFETY PRECAUTIONS .....................................................................2-2

2.01 Mesures de sécurité ......................................................................2-5

2.02 Precauciones de seguridad ...........................................................2-8

SECTION 3: SPOOL GUN SPECIFICATIONS .......................................................... 3-11

SECTION 4: STANDARD SETUP ...........................................................................4-12

SECTION 5: ESG-1 (STOCK NO. 1028-1295) .......................................................5-14

SECTION 6: LOADING THE SPOOL OF WIRE ........................................................6-16

SECTION 7: PRE-WELDING PROCEDURE ............................................................7-17

SECTION 8: CHANGING OR REPLACING DRIVE ROLLS .......................................8-18

SECTION 9: CONDUCTOR TUBE & LINER REPLACEMENT ................................... 9-19

SECTION 10: WIRING SCHEMATIC .................................................................... 10-20

SECTION 11: TROUBLESHOOTING .....................................................................11-21

SECTION 12: CONTACT TIP IDENTIFICATION AND PARTS LIST ........................ 12-22

12.01 Contact Tip Replacement ..........................................................12-23

12.02 Nozzles ......................................................................................12-23

SECTION 13: JUMP LINER INSTALLATION ........................................................13-24

SECTION 14: LINER GUIDE ASSEMBLY REPLACEMENT ....................................14-25

SECTION 15: REPLACEMENT PARTS .................................................................15-26

SECTION 16: STATEMENT OF WARRANTY ........................................................16-28

16.01 Warranty Schedule ....................................................................16-29

safety and operating instructions

1-189200011 Introduction

SECTION 1:

INTRODUCTION

1.01 HOW TO USE THIS MANUAL

To ensure safe operation, read the entire manual, including the chapters on safety instructions

and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular

attention to the information provided under these headings. These special annotations are

easily recognized as follows:

NOTE

NOTE conveys installation, operation, or maintenance information which is

important but not hazard-related.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may

result in injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

1.02 RECEIPT OF EQUIPMENT

When you receive the equipment, check it against the invoice to make sure it is complete and

inspect the equipment for possible damage due to shipping. If there is any damage, notify the

carrier immediately to ﬁle a claim. Furnish complete information concerning damage claims

or shipping errors to the location in your area, listed on the back cover of this manual. Include

a full description of the parts in error.

If you want additional or replacement copies of this manual, please contact Tweco

at the

address and phone number in your area listed on the back cover of this manual. Include the

Manual number (from page i)

1.03 DESCRIPTION

The SSG series of Eliminator spool guns is designed to provide smooth positive wire feed when

welding aluminum or steel structures. The MIG gun incorporates the same cablehoz® found

on other Tweco Professional MIG guns providing excellent electrical and abrasion resistant

characteristics. The MIG gun can operate at 300 amps @ 60% duty cycle with mixed gases.

The patented Eliminator contact tips come standard on the MIG gun allowing for quick changing

over the conventional threaded contact tip.

2-2

safety and operating instructions

89200011

SECTION 2:

SAFETY PRECAUTIONS

WARNING

SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not

properly installed, used, and maintained. Misuse of this equipment and other

unsafe practices can be hazardous. The operator, supervisor, and helper must read

and understand the following safety warnings and instructions before installing

or using any welding or cutting equipment, and be aware of the dangers of the

welding or cutting process. Training and proper supervision are important for a

safe work place. Keep these instructions for future use. Additional recommended

safety and operating information is referenced in each section.

WARNING

This product contains chemicals, including lead, or otherwise produces

chemicals known to the State of California to cause cancer, birth defects and

other reproductive harm. Wash hands after handling.

(California Health & Safety Code § 25249.5 et seq.)

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH

Install and maintain equipment in accordance with the National Electrical Code

(NFPA 70) and local codes. Do not service or repair equipment with power on.

Do not operate equipment with protective insulators or covers removed. Service

or repair to equipment must be done by qualified and/or trained

personnel only.

Do not contact electrically live parts. Always wear dry welding gloves that are in good condition.

Aluminized, protective clothing can become part of the electrical path. Keep oxygen cylinders,

chains, wires, ropes, cranes, and hoists away from any part of the electrical path. All ground

connections must be checked periodically to determine if they are mechanically strong, and

electrically adequate for the required current. When engaged in AC welding/cutting under wet

conditions or where perspiration is a factor, the use of automatic controls for reducing the no

load voltage is recommended to reduce shock hazards. Accidental contact must be prevented

when using open circuit voltage exceeding 80 volts AC, or 100 volts DC by adequate insulation

or other means. When welding is to be suspended for any length of time, such as during lunch

or overnight, all electrode holders and electrodes should be removed from the electrode holder

and the power supply should be turned off to prevent accidental contact. Keep MIG Guns,

electrode holders, Tig torches, Plasma torches, and electrodes away from moisture and water.

See safety and operating references 1, 2, and 8.

Safety Precautions

safety and operating instructions

2-389200011

SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH

Ventilation must be adequate to remove smoke, fumes, and gases during operation

to protect operators and others in the area. Vapors of chlorinated solvents can

form the toxic gas “Phosgene” when exposed to ultraviolet radiation from an

electric arc. All solvents, degreasers, and potential sources of these vapors must

be removed from the operating area. Use air-supplied respirators if ventilation

is not adequate to remove all fumes and gases. Oxygen supports, and vigorously accelerates ﬁre

and should never be used for ventilation.

See safety and operating references 1, 2, 3, and 4.

ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN

Welding and cutting processes produce extreme localized heat and strong

ultraviolet rays. Never attempt to weld/cut without a federally compliant welding

helmet with the proper lens. A number 12 to 14 shade ﬁlter lens provides the

best protection against arc radiation. When in a conﬁned area, prevent the

reﬂected arc rays from entering around the helmet. Approved shielding curtains

and appropriate goggles should be used to provide protection to others in the surrounding area.

Skin should be protected from arc rays, heat, and molten metal. Always wear protective gloves

and clothing. All pockets should be closed and cuffs sewn shut. Leather aprons, sleeves, leggings,

etc. should be worn for out-of-position welding and cutting, or for heavy operations using large

electrodes. Hightop work shoes provide adequate protection from foot burns. For added protection,

use leather spats. Flammable hair preparations should not be used when welding/cutting. Wear

ear plugs to protect ears from sparks. Where work permits, the operator should be enclosed in

an individual booth painted with a low reflective material such as zinc oxide.

See safety and operating references 1, 2, and 3.

WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS

Combustibles reached by the arc, ﬂame, ﬂying sparks, hot slag, and heated

materials can cause ﬁre and explosions. Remove combustibles from the work

area and/or provide a ﬁre watch. Avoid oily or greasy clothing as a spark may

ignite them. Have a ﬁre extinguisher nearby, and know how to use it. If welding/

cutting is to be done on a metal wall, partition, ceiling, or roof, precautions must

be taken to prevent ignition of nearby combustibles on the other side. Do not

weld/cut containers that have held combustibles. All hollow spaces, cavities, and containers

should be vented prior to welding/cutting to permit the escape of air or gases. Purging with inert

gas is recommended. Never use oxygen in a welding torch. Use only inert gases or inert gas

mixes as required by the process. Use of combustible compressed gases can cause explosions

resulting in personal injury or death. Arcing against any compressed gas cylinder can cause

cylinder damage or explosion. See safety and operating references 1, 2, 5, 7, and 8.

NOISE CAN DAMAGE HEARING

Noise from the air carbon-arc process can damage your hearing. Wear protective

hearing devices to ensure protection when noise levels exceed OHSA standards.

Adequate hearing protection devices must be worn by operators and surrounding

personnel to ensure personal protection against noise. See safety and operating

references 1, 2, and 6.

Safety Precautions

2-4

safety and operating instructions

89200011

SAFETY AND OPERATING REFERENCES

1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139, 251,

252, 253, 254 and 1000. U.S. Government Printing Ofﬁce, Washington, DC 20402.

2. ANSI Z49.1 “Safety in Welding and Cutting”.

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection”.

4. ANSI Z88.2. “Standard Practice for Respiratory Protection”. American National

Standards Institute, 1430 Broadway, New York, NY 10018.

5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers”.

6. AWS C5.3. “Recommended Practices for Air Carbon-Arc Gouging and Cutting”.

The American Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL

33135.

7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes”.

8. NFPA-7. “National Electrical Code”. National Fire Protection Association, Battery Park,

Quincy, MA 02269.

9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes”. Canadian Standards

Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.

DECLARATION OF CONFORMITY

Tweco

Products, Inc. declares under our sole responsibility that the product

Hand Held Air/Gas and Water Cooled MIG Welding Torches

To which this declaration relate(s) are in conformance with the following standards:

IEC 60974-7:2005

Following the provisions of the 73/23/EEC directive.

Safety Precautions

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safety and operating instructions

2-789200011 Safety Precautions

LE BRUIT PEUT ENDOMMAGER L’OUÏE

Le bruit du procédé de l’arc avec électrode en carbone et jet d’air peut endommager

l’ouïe. Portez un dispositif de protection de l’ouïe pour vous protéger lorsque le

niveau de bruit dépasse les normes de l’OSHA. Les opérateurs et le personnel aux

abords doivent porter un dispositif de protection de l’ouïe approprié pour les protéger

efﬁcacement contre le bruit. Voir les références en matière de sécurité et

d’utilisation n° 1, 2 et 6.

RÉFÉRENCES EN MATIÈRE DE SÉCURITÉ ET D’UTILISATION

1. Code of Federal Regulations (OSHA), section 29, partie 1910.95, 132, 133, 134,

139, 251, 252, 253, 254 et 1000. U.S. Government Printing Ofﬁce, Washington, DC

20402.

2. ANSI Z49.1 « Safety in Welding and Cutting ».

3. ANSI Z87.1 « Practice for Occupational and Educational Eye and Face Protection ».

4. ANSI Z88.2. « Standard Practice for Respiratory Protection ». American National

Standards Institute, 1430 Broadway, New York, NY 10018.

5. AWS F4.1. « Recommended Safe Practices for Welding and Cutting Containers ».

6. AWS C5.3. « Recommended Practices for Air Carbon-Arc Gouging and Cutting ».

The American Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL

33135.

7. NFPA 51B. « Fire Prevention in Cutting and Welding Processes ».

8. NFPA-7. « National Electrical Code » (code national de l’électricité). National Fire

Protection Association, Battery Park, Quincy, MA 02269.

9. CSA W117.2. « Règles de sécurité en soudage, coupage et procédés connexes ».

Association canadienne de normalisation, 178 boul. Rexdale, Rexdale, Ontario, Canada

M9W 1R3.

DECLARATION OF CONFORMITY

Tweco

Products, Inc. declares under our sole responsibility that the product

Hand Held Air/Gas and Water Cooled MIG Welding Torches

To which this declaration relate(s) are in conformance with the following standards:

IEC 60974-7:2005

Following the provisions of the 73/23/EEC directive.

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2-10

safety and operating instructions

89200011

EL RUIDO PUEDE DAÑAR LA AUDICIÓN

El ruido del proceso con arco de aire/carbón puede dañar su audición. Use dispositivos

de protección auditiva para contar con protección cuando los niveles superen las

normas de la OSHA. Los operadores y personal próximo deben usar protectores

auriculares para asegurar la protección contra el ruido. Consulte las referencias

de seguridad y uso 1, 2 y 6.

REFERENCIAS DE SEGURIDAD Y USO

1. Código de Normas Federales (OSHA), Sección 29, Partes 1910.95, 132, 133, 134,

139, 251, 252, 253, 254 y 1000. Oﬁcina de la Imprenta Gubernamental de los EE.UU.,

Washington, DC 20402.

2. ANSI Z49.1 “Safety in Welding and Cutting” (Seguridad en la soldadura y el corte).

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection” (Práctica

para la protección ocupacional y educativa de ojos y rostro).

4. ANSI Z88.2. “Standard Practice for Respiratory Protection” (Práctica estándar para

protección respiratoria). American National Standards Institute (Instituto norteamericano

de normas nacionales), 1430 Broadway, New York, NY 10018.

5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers” (Prácticas

seguras recomendadas para soldadura y corte de recipientes).

6. AWS C5.3. “Recommended Safe Practices for Air Carbon-Arc Gouging and Cutting”

(Prácticas seguras recomendadas para ranurado y corte con arco de aire/carbón). The

American Welding Society (Sociedad norteamericana de soldadura), 550 NW Lejeune

Rd., P.O. Box 351040, Miami, FL 33135.

7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes” (Prevención de incencios

en procesos de corte y soldadura).

8. NFPA-7. “National Electrical Code” (Código eléctrico nacional). National Fire Protection

Association (Asociación nacional para la protección contra incendios), Battery Park,

Quincy, MA 02269.

9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes” (Seguridad en procesos

de soldadura, corte y asociados). Canadian Standards Association (Asociación canadiense

de normas), 178 Rexdale Blvd., Rexdale, Ontario, Canadá M9W 1R3.

DECLARATION OF CONFORMITY

Tweco

Products, Inc. declares under our sole responsibility that the product

Hand Held Air/Gas and Water Cooled MIG Welding Torches

To which this declaration relate(s) are in conformance with the following standards:

IEC 60974-7:2005

Following the provisions of the 73/23/EEC directive.

Safety Precautions

safety and operating instructions

3-1189200011

SECTION 3:

SPOOL GUN SPECIFICATIONS

Example Part Number:

SSG 225 3545

Eliminator Spool Gun

300 Amp-25' (8M) Cable

.035" / .045" (0,9mm / 1,2mm)

Wire Diameter

Process: MIG/MAG welding

Voltage Class: L (up to 113V peak)

Type of Cooling: Air-Cooled

Duty Cycle: 300 Amps @ 60% Duty Cycle

Gas Flow Rate: 30 CFH / 14.2 l/m

Gun Length: 25 ft. (8M) & 50 ft. (15M)

Wire Size: .030" (0,8mm) to 1/16" (1,6mm)

Eliminator Spool Gun

Part No. Stock No. Connection Description

SSG225-3545 1027-1370

25mm Dinse

25 ft. (8M)

SSG250-3545 1027-1371 50 ft. (15M)

NOTE

The Dinse style connector can be removed and a lug (included) can be installed

for attachment to machines with studs.

Spool Gun Speciﬁcations

4-12

safety and operating instructions

89200011

SECTION 4:

STANDARD SETUP

NOTE

Be certain that the end user (welder, operator, or helper) reads and understands

these instructions. Be certain that the welder also reads Section 2, "Safety

Precautions."

WARNING

Electric shock can cause injury or death.

The Eliminator Spool Gun requires 24VDC power for the motor inside the handle to feed the

wire from the spool. For power supplies having the capability to supply the 24VDC, no added

modules will be required to operate this MIG gun. A 10-pin amphenol plug is attached to the

cord coming out of the rear of the MIG gun that can be either attached directly to the mating

connection on the machine or through jump cords, refer to available options noted below:

Control Wire Jumper Cords

Manufacturer Machine Part Number Stock Number

Miller Millermatic 210 WSPMIU4PJC2 2031-2246

Miller Millermatic 212 WSPMILLOPJC 2031-2246

Lincoln Power MIG 255C WSPLIN7PJC 2031-2247

Hobart Ironman 210, 250 WSPMILL4PJC 2031-2245

Esab Migmaster 203 WSPESAB7PJC 2031-2248

Esab Migmaster 253 WSPESAB7PJC 2031-2248

Esab Migmaster 250 WSPESAB7PJC 2031-2248

Generic See pin conﬁguration WSPESAB7PJC 2031-2249

For those that cannot supply the 24VDC from a power source, Part No. ESG-1 Solid State

Control Box (Stock No. 1028-1295) will be required to interface with the power source. Refer

to Section 5 on the operation of the ESG-1 control box.

NOTE

When connecting the Spool gun to a Thermal Arc Arcmaster & Power Master

series power sources, use the Thermal Arc SGI-100 Spool Gun interface box.

Follow the set-up procedures outlined in the SGI-100 Instruction Manual, Form

No. 0-5061.

Standard Setup

safety and operating instructions

4-1389200011

Gas Supply

Control Cable

Gas Line

ESG-1 Control

Tweco

Spool Gun

(Gas and

Control Lines)

Tweco Spool Gun

Work Table

Power Cord

Weld Cables

Power Source

FRONT VIEW

REAR VIEW

STANDARD SYSTEM OUTLINE

Mount the control box on the power source and attach the MIG gun to the power source

by using the 25mm dinse connector supplied with the gun or if the power supply has a

stud, remove the connector from the MIG gun and attach the lug option (supplied) to the

gun to make this connection.

a) One (1) straight power lug is furnished with the MIG gun if the connection of the MIG gun

can only be made with a lug. Remove the dinse connector from the MIG gun by using a

5/32” allen wrench to remove the socket head cap screw found on the brass connector.

b) Using the ﬂat head cap screw furnished with the lug, place the lug on the brass block

and secure the lug in place. This connection must be wrench tight.

Using the jumper cord, Part No. SSG300-106JC (Stock No. 2031-2150), connect the 10-pin

amphenol plug attached to the gun to the mating connection on the jumper cord. The opposite

end of the jump cord has a 6-pin connection that connects to the ESG-1 box.

3. Locate the two (2) cords coming from the back of the control box, one will not have a connector

attached. Strip the ends of the 2 wire cable and install the proper terminals required to connect

into the trigger circuit on the power source.

NOTE

On some machines it may require the leads to be attached directly to the contactor

relay inside the power source.

4. Attach the gas hose from the rear of the MIG gun to the gas hose connection on the front

side of the control box.

5. Attach the gas hose from the ﬂow meter/regulator to the rear of the control box.

6. Plug the 120V cord coming out of the rear of the control box to a suitable 120V outlet.

NOTE

For more information on the control box read the instructions furnished with the

ESG-1 control box.

Standard Setup

Figure 4-1: ESG-1 Connection

5-14

safety and operating instructions

89200011

SECTION 5:

ESG-1 (STOCK NO. 1028-1295)

The ESG-1 is a solid state control for the Tweco Spool gun assembly. It's responsible for the

on/off ﬂow of shielding gas to the gun including pre-ﬂow and post-ﬂow, the on/off ﬂow of the

welding current from the power source, the run-in speed of the ﬁller metal during arc initiation,

and the constant wire feed speed of the ﬁller metal while welding.

Front Panel Controls & Connections

1. Located on the front panel are three (3) potentiometers that allows control of the following

functions;

t-1 - This knob is used to select the amount of pre-ﬂow time desired. The range of pre-

ﬂow time control is 0 - 2.5 seconds.

t-2 - This knob is used to select the amount of post-ﬂow time desired. The range of post-

ﬂow time control is 0 - 2.5 seconds.

O/O - This knob controls the run-in speed of the ﬁller metal towards the workpiece.

2. Spool gun connection (GAS) - the spool gun gas ﬁtting plugs into this connection. Shielding

gas is delivered to the spool gun through this connection.

3. Spool gun connection (CONTROL) - The spool gun control cable plugs into this receptacle.

The ESG-1 and the spool gun communicate with one another through the following pins:

a) Pin A - Motor Voltage (+)

b) Pin B - Motor Voltage (-)

c) Pin C - Gun Switch Output

d) Pin D - Wire Feed Speed Maximum

e) Pin E - Wire Feed Speed Reference

f) Pin F - Wire Feed Speed Minimum

Spool Gun

Connection

(CONTROL)

Spool Gun

Connection

(GAS)

Pre-Flow

Control

(0 - 2.5 sec)

Post-ﬂow

Control

(0 - 2.5 sec)

Run-In

Speed

Control

Figure 5-1: Front Panel Controls and Connection

ESG-1

safety and operating instructions

5-1589200011

Rear Panel Controls & Connections

1. Power Cord - The power cord plugs into a 120VAC outlet to get input power to the ESG-1.

Outlets found on the power source are acceptable.

2. Control Cable - The control cable connects to the power source. After depressing the gun

switch on the spool gun, an internal relay on the ESG-1 provides closure between the two

wires of the control cable. This closure is then used to energize the power source.

NOTE

The control cable will have to be adapted to properly mate with the power

source I/O device.

3. Gas Valve Inlet - This is where the shielding gas hose from the gas supply is connected to

the ESG-1. The gas valve inlet controls the on/off ﬂow of shielding gas through the spool

gun assembly.

4. Primary Circuit Breaker - The circuit breaker provides protection against faults or overloads

on the primary side of the circuit.

5. Secondary Circuit Breaker - This circuit breaker provides protection against faults or

overloads on the secondary side of the circuit.

Gas Valve Inlet

Primary Circuit

Breaker

Secondary Circuit

Breaker

Power Cord

Control Cable

Figure 5-2: Rear Panel Connections

ESG-1

6-16

safety and operating instructions

89200011

SECTION 6:

LOADING THE SPOOL OF WIRE

1. Load a spool of wire by loosening the

outer knob on the spool cover and

removing the cover.

2. Hold the spool of wire above the

opening while exposing 3” (76,2mm)

of wire away from the spool.

3. Straighten the wire to remove the normal cast and begin lowering the spool downward

over the shaft while inserting the straightened wire into the wire guide.

4. When the wire is positioned between

the drive rolls, adjust the drive roll

pressure to engage the wire enough to

begin feeding the wire forward through

the conductor tube. The spool should

be lowered in place while the wire is

feeding into the conductor tube.

5. Replace the cover and tighten the outer knob.

6. Make ﬁnal adjustments to the drive roll pressure and adjust the spool brake with

the inner knob of the spool cover.

7. Adjust voltage and wire speed to that recommended by the wire manufacturer.

8. The gun is now ready for operation.

Loading the Spool of Wire

safety and operating instructions

7-1789200011 Pre-Welding Procedure

SECTION 7:

PRE-WELDING PROCEDURE

1. Make sure all connections have been made.

2. Turn the power source “on”.

3. Adjust the ﬂow of the shielding gas to the desired level.

NOTE

The gun trigger on the spool gun assembly will have to be depressed to allow

gas ﬂow.

4. If using the ESG-1 control box, adjust the run-in speed of the ﬁller metal to the desired

value by means of the run-in speed control located on the front panel of the ESG-1.

5. Adjust the wire speed of the ﬁller metal to the desired value by means of the wire feed

speed control located in the handle of the spool gun assembly.

6. Adjust the voltage of the power source to the desired value by means of the voltage control

located on the power source.

8-18

safety and operating instructions

89200011

SECTION 8:

CHANGING OR REPLACING DRIVE ROLLS

1. Guns are shipped standard with 3/64” (1,2mm) drive rolls installed. Optional drive rolls

are available for .030” (0,8mm) through 1/16” (1,6mm) wire, see below table.

Optional Drive Rolls

Wire Size Part No. Stock No.

.030” (0,8mm) EPG103-2-0,8 2031-2091

.035” (0,9mm) EPG103-2-0,9 2031-2077

.040” (1,0mm) EPG103-2-1,0 2031-2023

3/64” (1,2mm) EPG103-2-1,2 2031-2003

1/16” (1,6mm) EPG103-2-1,6 2031-2022

2. To change or replace drive roll, loosen the setscrew on the drive roll with the allen wrench

furnished.

3. Remove the drive roll from the motor shaft and reinstall the new drive roll in its place.

NOTE

Make sure that the drive roll is seated against the brass washer before tightening

the set screw.

4. Drive rolls have two u-grooves in each roll and maybe inverted to double the life of one

drive roll.

Changing or Replacing Drive Rolls

safety and operating instructions

9-1989200011

SECTION 9:

CONDUCTOR TUBE & LINER REPLACEMENT

Conductor Tubes

Part No. Stock No. Description

PMP64EL-180 1642-1140 180° Rigid Conductor Tube (Standard)

PMP64EL-30 1642-1141 30° Rigid Conductor Tube

PMP64SFLX-360 1642-1142 Knucklehead

™

Flexible Conductor Tube

1. To remove and replace the conductor tube from the MIG gun, unscrew the insulated

conductor tube-retaining nut from the front end of the gun.

2. To remove the liner within the conductor tube, remove the nozzle from the conductor tube.

3. Unscrew the gas diffuser and remove.

4. Pull the liner out of the conductor tube and cut the replacement liner to the same length

as the one removed.

5. Remove any obstructions to the liner that may be present after cutting to length and insert

into the conductor tube.

NOTE

Make sure the liner ﬁts into the front wire guide in the gun body.

6. Reinstall the nozzle.

Conductor Tube & Liner Replacement

10-20

safety and operating instructions

89200011

SECTION 10:

WIRING SCHEMATIC

BEND

SOLDERED

TABS OVER

AS SHOW

ORIENT WIRES

ON THE SIDES

AS SHOW

ORANGE

ESG89-F

POTENTIOMETER

SUB-ASSY

ESG90-F

MICRO SWITCH

SUB-ASSY

RED LEAD

TRIM 9” LG

EPG-24-MTR-F

SPURGEAR MOTOR

SUB-ASSY

BLA

LEAD

TRIM

9” LG.

YELLOW

BLUE

GREEN

WHITE

PINK

GREY

CABLEHOZ CONTROL

LEAD WIRE

Wiring Schematic

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ESAB Air-Cooled SSG Series 300 AMP ELIMINATOR® Spool Gun User manual

Brand: ESAB

Model: Air-Cooled SSG Series 300 AMP ELIMINATOR® Spool Gun

Category: Welding System

Type: User manual

Download PDF

report

ESAB Air-Cooled SSG Series 300 AMP ELIMINATOR® Spool Gun User manual

ESAB Air-Cooled SSG Series 300 AMP ELIMINATOR® Spool Gun User manual

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