PowCon SGS 30A, Owner'S Manual

Page 1: ...Processes OM 183 304A September1998 SGS 30A Description MIG GMAW Welding Feeder Gun ...

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Page 3: ...el For CE Products 7 2 2 Symbols And Definitions 7 SECTION 3 INSTALLATION 8 3 1 Specifications 8 3 2 Removing Top Cover 8 3 3 Adjusting Contact Tip Position 8 3 4 Installing Wire Spool And Threading Welding Wire 9 3 5 Rotating Canister 9 3 6 Connecting To 24 Volt Weld Control 10 3 7 Installing Gas Supply 11 3 8 Adjusting Drive Roll And Spool Brake Pressure 12 SECTION 4 OPERATION 13 4 1 Controls 13...

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Page 5: ...EC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Arc Welding Equipment Part I Welding Power Sources IEC 974 1 April 1995 Draft Revision Arc Welding Equipment Wirefeed Systems IEC 974 4 May 1995 Draft Revision Degrees of Protection Provided By Enclosures IP Code IEC 529 1989 Insulation Coordination For Equipment With Low Voltage Systems Part I Principles Requirements an...

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Page 7: ...amaged undersized or poorly spliced cables 11 Do not drape cables over your body 12 If earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable 13 Do not touch electrode if you are in contact with the work ground or another electrode from a different machine 14 Use only well maintained equipment Repair or replace damaged parts at onc...

Page 8: ...rent from traveling long possibly unknown paths and causing electric shock and fire hazards 9 Do not use welder to thaw frozen pipes 10 Remove stick electrode from holder or cut off welding wire at contact tip when not in use 11 Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap 12 Remove any combustibles such as a butane lighter or matches ...

Page 9: ...Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 EMF Information ConsiderationsAbout Welding And The Effects Of Low Frequency Electric And Ma...

Page 10: ...des nationaux provin ciaux et municipaux 6 Toujours vérifier la terre du cordon d alimentation Vérifier et s as surer que le fil de terre du cordon d alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre 7 En effectuant les raccordements d entrée fixer d abord le conduc teur de mise à la terre approprié et...

Page 11: ... produire des étincelles Des étincelles une pièce chaude et un matériel chaud peuvent provoquer des incendies et des blessures Le contact accidentel de l électrode sur des objets métalliques peut produire des étincelles l explosion la surchauffe ou un incendie S assurer que le lieu ne présente pas de danger avant d effectuer le soudage 1 Se protéger et protéger les personnes à proximité des étince...

Page 12: ...ra pidement par un électricien qualifié les problèmes d intrférences résultant de l installation 3 Dans le cas d un avertissement d interférence don né par le Conseil fédéral des communications ar rêter d utiliser immédiatement l équipement 4 Faire vérifier et entretenir régulièrement l installa tion 5 Tenir les portes et panneaux de la source de haute fréquence bien fermés maintenir les éclateurs...

Page 13: ...s les résultats obte nus sont complexes Dans l état actuel de nos connaissances dans le domaine scientifique nous ne sommes pas en mesure d inter préter nos observations à la lumière d une théorie générale Et ce qui est encore plus regrettable nous ne pouvons rien affirmer de définitif au sujet des risques éventuels ni proposer des méthodes scientifi ques précises pour réduire ces risques ou pour ...

Page 14: ...on 4 1 PowCon Incorporated San Diego CA USA U1 30V I1 1A IP 23 U2 100V I2 200A X 100 S 182 589 2 2 Symbols And Definitions Some symbols are found only on CE products NOTE U1 Primary Voltage V Volts I1 Primary Current A Amperes IP Degree Of Protection U2 Conventional Load Voltage I2 Rated Welding Current X Duty Cycle Percent ...

Page 15: ...tallation If contact tip liner and drive roll groove are not correct for wire size and type see Section 5 to change parts as needed See Parts List for other available contact tips NOTE 3 2 Removing Top Cover Ref 150 882 A 1 Top Cover Push back and lift off as shown To reinstall cover set rear of cover in gun feeder and push cover back down and forward until it clicks into position 1 3 3 Adjusting ...

Page 16: ...ntact Tip Thread wire through canister inlet guide along drive roll groove and out contact tip Install spool so wire feeds off bottom 10 Spool Brake Thumbnut If necessary turn thumbnut coun terclockwise slightly to install spool 11 Thumbscrew Canister Rotation Loosen thumbscrew to rotate can ister see Section 3 5 Close and secure pressure roll assembly Reinstall top cover and canister cover Tools ...

Page 17: ...ct fitting to gun feeder gas hose and remaining end to regula tor flowmeter see Section 3 7 3 24 Volt Weld Control 4 Trigger Control Cord Insert plug into receptacle and tighten threaded collar 5 Weld Cable Connect to positive weld output terminal on welding power source according to its Owner s Manual Tools Needed 1 1 8 5 8 in 1 2 3 4 5 ...

Page 18: ...om valve Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Gas Hose Connection Fitting has 5 8 18 right hand threads 6 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire manufactur er s recommended flow rate Make sure flow adjust is closed when opening cylinder to avoid damage to the flowmeter 7 CO2 Adapter 8 O Ring Install adapter with O ring between r...

Page 19: ... while adjusting spool brake thumb nut When a slight force is needed to turn spool tension is set Do not overtighten Reinstall canister cover Thread welding wire see Section 3 4 6 Drive Roll Tension Thumbnut Turn On unit and check drive roll pressure by feeding wire against a wood board or concrete surface wire should feed steadily without slipping Adjust drive roll tension thumbnut if necessary D...

Page 20: ...sing the trigger release trigger and wire continues to feed until trigger is pressed again 3 Wire Speed Control Use control to adjust wire feed speed The numbers in the opening are not a wire feed speed and are for reference only 4 Rating Label Location 1 2 3 4 4 2 Shielding Gas sb5 1 6 92 S 0621 C Ref 147 741 A 1 Shielding Gas Cylinder 2 Valve 3 Gun Trigger Open valve on cylinder just before weld...

Page 21: ...ing Contact Tip And Liner 150 437 Remove top cover and open pres sure roll assembly as shown in Section 5 3 1 Contact Tip Wrench Insert wrench into nozzle over con tact tip 2 Compression Nut Loosen nut Pull out contact tip 3 Contact Tip 4 Nozzle Pull wire out nozzle and liner should slide out If necessary tilt nozzle down to remove liner Close pressure roll assembly Re install top cover Install ne...

Page 22: ...st Lightly grease top of tab before rein stalling 3 Drive Roll Use wire brush to clean drive roll Install drive roll with desired groove down and turn drive roll so one set screw faces flat side of shaft 4 Bearing Use wire brush to clean bearing Line up drive roll groove with bear ing groove and liner opening Tight en setscrews Thread welding wire through gun see Section 3 3 in the Owner s Manual ...

Page 23: ...e roll assembly Ad just spool brake pressure and drive roll pressure if necessary see Sec tion 3 8 Reinstall covers Tools Needed 1 2 3 4 5 6 7 8 5 5 Replacing Spool Canister Ref 149 967 B 1 Top Cover 2 Pressure Roll Assembly Cut off welding wire where it enters pressure roll assembly area 3 Nozzle Pull wire out nozzle 4 Thumbscrew Canister Rotation Turn thumbscrew counterclock wise three full turn...

Page 24: ...n see welding power source Owner s Manual Erratic weld output Tighten and clean all connections Pressing gun feeder trigger does not en ergize weld control welding wire is not energized shielding gas does not flow Secure plug from gun feeder trigger cord into 10 socket receptacle on weld control see Section 3 6 Wire does not feed burnback in contact tip Reinstall current pick up tab if applicable ...

Page 25: ...OM 222 Page 19 SECTION 6 ELECTRICAL DIAGRAMS 138 956 B Figure 6 1 Circuit Diagram For Gun Feeder ...

Page 26: ...OM 183 304 Page 20 Notes ...

Page 27: ...em 71 Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 10 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 23 29 30 31 32 83 34 33 35 36 35 84 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 58 59 60 61 62 71 63 64 65 66 43 67 68 35 70 69 72 73 74 75 76 77 78 79 80 81 82 ...

Page 28: ...contact 047 61 wire 1 19 135 426 TIP contact 062 73 wire 1 19 135 425 TIP contact 062 81 wire 1 136 821 WRENCH nut tip contact 1 166 575 WRENCH hex 078 across the flat 1 20 136 748 NUT 375 24 41dia stl 1 21 136 683 LINER teflon 045 1 16 wire x 6 875 lg 1 21 136 682 LINER teflon 023 035 wire x 6 875 lg 1 22 164 421 ADAPTER contact tip 1 23 164 485 O RING 176 ID x 070CS 2 24 604 612 SCREW set 8 32 x...

Page 29: ...591 CASE gun LH 1 64 173 527 SCREW 8 32 x 1 500 2 65 135 896 PLUNGER trigger hold 1 66 173 528 SCREW 8 32 x 875 1 67 B2 161 813 MOTOR gear PM 24VDC 420RPM 10 2 1 ratio 1 68 164 592 TRIGGER 1 69 164 582 HOUSING wire drive consisting of 1 70 058 262 CAP valve 1 71 135 580 FITTING gas 1 146 555 SCREW set 8 32 x 125 cup sch 2 72 009 925 NOZZLE spot outside corner 937 ID x 2 375 1 73 050 116 NOZZLE 13 ...

Page 30: ...ze contact tips to accommodate all wire sizes Uses standard straight barrel head tube liner REPLACEMENT CONTACT TIPS FOR CURVED NOZZLE 148 155 030 and 035 in 0 8 and 0 9 mm wire 148 154 047 in 1 2 mm wire 148 156 1 16 in 1 6 mm wire 3 IN HEAD TUBE EXTENSION 137 787 Extends the standard gun barrel 3 in 72 mm when a longer reach is required The head tube extension is supplied with two liners to acco...

Page 31: ...ware has been used in a manner for which it was neither designed nor manufactured improperly maintained modified without authorization or otherwise ill treated Transportation charges to send products to an authorized warranty repair facility or PowCon Incorporated shall be the responsibility of the customer All returned goods shall be at the customer s risk and expense Warranty claims must be subm...

Page 32: ...l Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department Resources Available Owner s Record File a...