Miller GA-50GL Owner's manual

Miller
Brand
Miller
Model
GA-50GL
Category
Welding System
Type
Owner's manual

This manual is also suitable for

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
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
9
SECTION
6-
PARTS
LIST
Available
Wire
Sizes
1.6MM
1.8MM
2.0MM
2.4MM
2.8MM
3.2MM
.063
.068/.072
.079
.094
.110
.126
1/16
.068/.072
5/64
3/32
7/64
1/8
Figure
6-1.
Exploded
View
Of
Gun
(Gun
With
1/16
Wire
Illustrated)
18
Ret.
TC-045
113
5
6
iii
~
10
12J
13
15
19
OM1532
Page
6
Item
Part
No.
No.
Description
Quanti
y
FIgure
6-1.
Exploded
View
Of
Gun
Assembly
1
009 709
TUBE,
contact
1/16
wire
1
1
090
922
TUBE,
contact
.068/.072
wire
1
1
052
055
TUBE,
contact
5/64
wire
1
1
008
926
TUBE,
contact
3/32
wire
1
1
008
925
TUBE,
contact
7/64
wire
1
1
008
924
TUBE,
contact
1/8
wire
1
2
046
017
PROTECTOR,
thread
1
3
046018
TUBE,hd6odeg
1
4
008
932
INSULATOR,
handle
1
5
008
931
LINER,
monocoil
7-1/4
Ig
1
6
075
625
KIT,
connector
hd
tube
(consisting
of)
1
7
075
855
INSULATOR,
nut
1
8
075
626
NUT,
brs
1
9
078
981
RING-HALF,
gun
2
10
008
948
GUARD,
w/clp
(consisting
of)
1
11
010860
CLAMP,
13/16-1-3/4clpdia
1
12
008
928
GUARD
1
13
602
178
SCREW,
set
skt
hd
1/4-20
x
1/4
1
14
075628
HANDLE,gun
1
15
073357
CUP,Iubricator
1
16
605 789
SCREW,
set
skt
hd
10-24
x
1/4
1
17
134
601
SLEEVE,
centering
-
monocoil
1
18
134
600
GUIDE,
wire
outlet
1/16
&
5/64
wire
I
18
079851
GUIDE,wireoutlet3/32-1/8wire
1
19
048
827
CABLE/CONDUIT,
lOft
(consisting
of)
1
19
048
826
CABLE/CONDUIT,
15ft
(consisting
of)
1
20
085
210
.
ADAPTER,
gun/feeder
1
21
004
733
.
CLAMP,
cable
2
22
004
732
CLAMP,
cable
2
23
004
729
ADAPTER,
hd
tube/pwr
cable
1
24
075
644
INSULATOR,
body
lubricator
1
25
095949
SPRING,
cprsn
1
26
114974
LINER,
monocoil
1/16-5/64
wire
lOft
1
26
088
758
LINER,
monocoil
3/32-1/8
wire
loft
1
26
114
973
LINER,
monocoil
1/1
6-5/64
wire
l5ft
1
26
008
759
LINER,
monocoil
3/32-1/8
wire
15ft
1
27
078
894
SCREW,
flat
hd
1/4-20
X
3/8
1
+046
013
NOZZLE,
scr
1-3/4
Ig
1
+046
014
NOZZLE,
scr
2-3/8
Ig
1
085
210
ADAPTER,
gun/feeder
.045
wire
1
076
123
COMPOUND,
cable
lubricant
1
079
885
TRIGGER
SWITCH,
lOft
1
079
854
TRIGGER
SWITCH,
l5ft
1
Optional
Equipment
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1532Pa
e7
OPTIONS
AND
ACCESSORIES
Wire
Size
1/16
(1.
6
mm)
.068/.072
(1.8
mm)
5/64
(2
mm)
3/32(2.4
mm)
7/64
(2.8
mm)
1/8
(3.2
mm)
INSULATED
WIRE
GUIDES
(Nozzles)
Stock
No.
040
013
1-3/4
(44
mm)
long
for
1-1/4
(32
mm)
to
1-3/4
(44
mm)
Elec
trical
Stick-Out
Stock
No
Stock
No.
046
014
--
2-3/8
(61
mm)
long
for
2
(51
mm)
to
2-1/2
(64
mm)
Electrical
Stick-Out
THREAD
PROTECTOR
(Standard)
Stock
No.
046 017
REPLACEMENT
LINERS
Stock
No.
Wire
Size
______
lOft.
(3
ml
15
ft.
14.6
m
1/16
(1.6
mm)
and
5/64
(2
mm)
009624 009625
3/32
(2.
4mm)
through
1/8
(3.2
mm)
048
823 048
824
HAND-HELD
FLUX
HOPPER
Stick
No.
046
728
(Factory),
052
789
(Field)
For
manual
Submerged
Arc
applications.
NOTE:
The
head
tube
is
not
threaded
and
will
not
accept
the
insulated
wire
guides
or
thread
pro
tector.
TRIGGER
SWITCH
10
(3
ml
Stock
No.
079 855
15
(4.6
m)
Stock
No.
079 854
Includes
cord
and
plug.
Required
when
used
with
Swingarcs,TM
PORTA~MlG,TM
or
the
50
Series
feeders.
1
3/4
Insulated
Wire
Guide
2
3/8
Insulated
Wire
Guide
CONTACT
TUBES
009 709
090
922
052
055
008
926
008 925
008 924
4/88
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Miller GA-50GL Owner's manual

Miller
Brand
Miller
Model
GA-50GL
Category
Welding System
Type
Owner's manual
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