Miller Electric Welder GA 16C User Manual

OM-1027  
110 727A  
August 1994  
Processes  
MIG (GMAW) Welding  
Flux Cored (FCAW) Welding  
Description  
Air-Cooled Gun  
GA-16C And GA-16C1  
Visit our website at  
 
SAFETY PRECAUTIONS FOR GMAW GUNS  
GMAW WELDING can be hazardous.  
WARNING  
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN  
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.  
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The  
safety information given below is only a summary of the more complete safety information found in the wire feeder  
and welding power source Owners Manuals. Read and follow all safety precautions.  
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY  
QUALIFIED PEOPLE.  
ELECTRIC SHOCK can kill.  
ARC RAYS can burn eyes and skin.  
1. Always wear dry insulating gloves.  
2. Insulate yourself from work and ground.  
3. Do not touch live electrode or electrical parts.  
4. Repair or replace worn, damaged, or cracked  
gun or cable insulation.  
5. Turn off welding power source before changing  
contact tip or gun parts.  
1. Wear welding helmet with correct shade of filter.  
2. Wear correct eye and body protection.  
3. Cover exposed skin with spatter-resistant  
clothing.  
HOT SURFACES can burn skin.  
1. Allow gun to cool before touching.  
2. Do not touch hot metal.  
6. Keep all covers and handle securely in place.  
3. Protect hot metal from contact by others.  
NOISE can damage hearing; SOME  
APPLICATIONS, SUCH AS PULSING,  
are noisy.  
FUMES AND GASES can be hazardous  
to your health.  
1. Check for noise level limits exceeding those  
specified by OSHA.  
1. Keep your head out of the fumes.  
2. Ventilate area, or use breathing device.  
2. Use approved ear plugs or ear muffs if noise level  
is high.  
3. Warn others nearby about noise hazard.  
3. Read Material Safety Data Sheets (MSDSs) and  
manufacturers instructions for material used.  
WELDING WIRE can cause puncture  
wounds.  
WELDING can cause fire or explosion.  
1. Keep hands and body away from gun tip when  
trigger is pressed.  
1. Do not weld near flammable material.  
2. Do not weld on closed containers.  
3. Watch for fire; keep extinguisher nearby.  
EMF INFORMATION  
Considerations About Welding And The Effects Of Low Frequency Electric And  
Magnetic Fields  
NOTE  
The following is a quotation from the General Conclusions Section of  
the U.S. Congress, Office of Technology Assessment, Biological  
Effects of Power Frequency Electric & Magnetic Fields –  
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.  
GovernmentPrinting Office, May 1989): . . . there is now a very large  
volume of scientific findings based on experiments at the cellular  
level and from studies with animals and people which clearly  
establish that low frequency magnetic fields can interact with, and  
produce changes in, biological systems. While most of this work is  
of very high quality, the results are complex. Current scientific  
understandingdoes not yet allow us to interpret the evidence in a  
single coherent framework. Even more frustrating, it does not yet  
allow us to draw definite conclusions about questions of possible risk  
or to offer clear science-based advice on strategies to minimize or  
avoid potential risks.”  
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 side and away from the operator.  
3. Do not coil or drape cables around the body.  
4. Keep welding power source and cables as far away as practical.  
5. Connect work clamp to workpiece as close to the weld as  
possible.  
About Pacemakers:  
The above procedures are among those also normally  
recommended for pacemaker wearers. Consult your doctor for  
complete information.  
mod10.1 4/93  
sr7 7/93  
 
 
SECTION 1 – SAFETY INFORMATION  
mod1.1 2/93  
Read all safety messages throughout this manual.  
Obey all safety messages to avoid injury.  
Learn the meaning of WARNING and CAUTION.  
1
2
Safety Alert Symbol  
Signal Word  
1
2
2
WARNING means possible death  
or serious injury can happen.  
WARNING  
CAUTION  
3
4
CAUTION means possible minor  
injury or equipment damage can  
happen.  
ELECTRIC SHOCK can kill.  
MOVING PARTS can injure.  
Do not touch live electrical parts.  
Keep away from moving parts.  
Disconnect input power before  
Keep all panels and covers closed  
3
Statement Of Hazard And Re-  
sult  
installing or servicing.  
when operating.  
4
Safety Instructions To Avoid  
Hazard  
5
5
6
Hazard Symbol (If Available)  
Safety Banner  
READ SAFETY BLOCKS at start of  
Section 3-1 before proceeding.  
WARNING  
Read safety blocks for each sym-  
bol shown.  
6
7
7
NOTE  
Turn Off switch when using high frequency.  
Special instructions for best oper-  
NOTE  
ation not related to safety.  
Figure 1-1. Safety Information  
SECTION 2 – SPECIFICATIONS  
Table 2-1. Welding Gun  
Specifications  
Description  
Rated Output  
Duty Cycle  
Wire Diameter  
Weight  
160 Amperes Using CO Shielding Gas Air-Cooled  
2
See Figure 2-1  
.023 And .030 in (0.6 And 0.8 mm) Hard Or Flux-Cored Wires  
10 ft Gun Net: 2.8 lb (1.3 kg); Ship: 5.4 lb (2.4 kg)  
2-1. Duty Cycle  
CAUTION  
WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty.  
Do not weld at rated load longer than shown below.  
wfwarn8.1 8/93  
0
Definition  
10  
Duty Cycle is percentage of 10  
Minutes  
minutes that gun can weld at  
rated load without overheating.  
60% Duty Cycle At 160 Amperes Using CO Gas  
30% Duty Cycle At 160 Amperes Using Mixed Gases  
2
6 Minutes Welding  
4 Minutes Resting  
3 Minutes Welding  
7 Minutes Resting  
sb1.5 8/93  
Figure 2-1. Duty Cycle  
OM-1027 Page 1  
 
SECTION 3 INSTALLATION  
3-1. Preparing And Installing Gun  
GA-16C Model  
1
2
3
Gun Securing Nut  
Drive Assembly  
Gun End  
Loosen securing nut. Insert gun  
end through opening until it bottoms  
against drive assembly. Tighten  
nut.  
3
4
Gun Trigger Plug Or  
Terminals  
Insert into receptacle and tighten  
threaded collar, or connect to  
matching terminals inside unit.  
4
1
2
Close door.  
See wire feeder manual for thread-  
ing procedure.  
GA-16C1 Model  
3
Tools Needed:  
5/16 in  
4
1
2
Ref. ST-151 357 / Ref. ST-149 629-C / Ref. ST-155 506  
Figure 3-1. Installing Gun  
SECTION 4 OPERATION  
READ SAFETY BLOCKS at beginning  
of manual before proceeding.  
WARNING  
4-1. Operating The Gun  
1
Trigger Switch  
When pressed, energized wire  
feeds and shielding gas flows.  
1
Ref. S-0621-C  
Figure 4-1. Using Gun Switch  
OM-1027 Page 2  
 
SECTION 5 MAINTENANCE & TROUBLESHOOTING  
READ SAFETY BLOCKS at beginning  
of manual before proceeding.  
WARNING  
5-1. Maintenance And Troubleshooting  
3 Months  
Each Spool Of Wire  
Turn Off all power before  
maintaining.  
Replace  
Cracked  
Parts  
Blow Out  
Gun  
Casing  
See  
Section  
5-2  
– –  
Control Cord  
Gun Cable  
Clean  
Nozzle  
And Check  
Contact Tip  
– –  
Gas Hose  
Figure 5-1. Routine Maintenance  
Table 5-1. Troubleshooting  
Trouble  
Remedy  
Wire does not feed.  
Check contact tip. Check for kinks in gun cable. Check trigger connection at  
welding power source/wire feeder. Have nearest Factory Authorized Service  
Station/Service Distributor check gun trigger switch.  
Wire is not energized.  
Wire feeds unevenly.  
Check contact tip. Check trigger connection at welding power source/wire feed-  
er. Have nearest Factory Authorized Service Station/Service Distributor check  
gun trigger switch.  
Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing.  
5-2. Changing Contact Tip And Liner  
Turn off welding power source/wire  
feeder. Cut off wire at nozzle.  
1
2
3
Nozzle  
3
Contact Tip  
2
Contact Tip Adapter  
1
Tools Needed:  
Ref. ST-149 326-A  
Figure 5-2. Changing Contact Tip  
OM-1027 Page 3  
 
CAUTION  
FLYING METAL CHIPS AND DIRT can cause injury and damage equipment.  
Point gun away from people and in a safe direction when blowing out with compressed air.  
Turn off welding power  
source/wire feeder.  
Head Tube  
3/8 in  
Remove nozzle,  
contact tip, and  
liner collet.  
3/8 in  
Remove liner.  
To Reassemble Gun:  
Install contact tip.  
Insert new liner.  
Gun/Feeder  
Connector  
Blow out  
gun casing.  
Install 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 pos-  
sible without touching.  
Tools Needed:  
Install nozzle.  
3/8 in  
Ref. ST-155 509  
Figure 5-3. Changing Liner  
OM-1027 Page 4  
 
SECTION 6 PARTS LIST  
Item  
No.  
Part  
No.  
Description  
Quantity  
Figure 6-1. Complete Assembly (GA-16C Gun Illustrated)  
. . . 1 . . . . . . . . . . 110 793 . . HANDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . . . . . . . . 110 795 . . TUBE, head (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . . . . . . . . . 110 780 . . . . NUT, M 10 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 4 . . . . . . . . . . 110 779 . . . . JACKET, head tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 5 . . . . . . . . . . 110 781 . . . . STOP, nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 6 . . . . . . . . . . 128 878 . . . . ADAPTER, head tube nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 7 . . . . . . . . . . 110 782 . . . . SPRING, nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . 110 785 . . TIP, contact .023 (16C Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . . . . . . . . 110 786 . . TIP, contact .030 (16C1 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . . . 110 789 . . NOZZLE, slip type 1/2 orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . 112 420 . . NOZZLE, slip type 3/8 orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . 110 790 . . NOZZLE, spot flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 9 . . . . . . . . 110 791 . . NOZZLE, spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . . . . . . . . 110 794 . . TRIGGER SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . . . . . . . . 080 565 . . TERMINAL, frict uninsul fem 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . . . . . . . . . . 110 792 . . CABLE, 10ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 13 . . . . . . . . . . 110 797 . . SLEEVE, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 14 . . . . . . . . . . 167 440 . . LINER, monocoil .023-.035 wire 10ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . 110 784 . . . . COLLET, liner .023-.030 wire (16C Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . 120 715 . . . . COLLET, liner .035 wire (16C1 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 16 . . . . . . . . . . 079 974 . . O-RING, 1/2 ID x .103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 17 . . . . . . . . . . 110 796 . . CONNECTOR, gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . 079 878 . . CONNECTOR & PINS, (16C Model) (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . 079 535 . . . . CONNECTOR, circ pin push-in 14-18ga Amp 66359-6 . . . . . . . . . . . . . . . . . 4  
. . . 18 . . . . . . . . . . 047 994 . . TERMINAL, frict ultrafast fem 22-18ga (16C1 Model) . . . . . . . . . . . . . . . . . . . . 2  
. . . 19 . . . . . . . . . . 048 834 . . CONNECTOR, circ clamp str rlf sz 11 Amp 206062-4 (16C Model) . . . . . . . . 1  
9
. Hardware is common and  
8
not available unless listed.  
7
6
2
5
4
10  
3
1
14  
1
15  
11  
12  
13  
16  
17  
1
3
18  
19  
Ref. ST-110 832-D  
Figure 6-1. Complete Assembly (GA-16C Gun Illustrated)  
OPTIONAL  
To maintain the factory original performance of your equipment, use only Manufacturers Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-1027 Page 5  
 
Notes  
 
Effective January 1, 2000  
(Equipment with a serial number preface of LAor newer)  
This limited warranty supersedes all previous Miller warranties and is exclusive with no other  
guarantees or warranties expressed or implied.  
Warranty Questions?  
LIMITED WARRANTY Subject to the terms and conditions  
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants  
to its original retail purchaser that new Miller equipment sold  
after the effective date of this limited warranty is free of defects  
in material and workmanship at the time it is shipped by Miller.  
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER  
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE  
WARRANTIES OF MERCHANTABILITY AND FITNESS.  
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting  
Torches  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
*
*
*
*
*
Remote Controls  
Accessory Kits  
Replacement Parts (No labor)  
Spoolmate 185 & Spoolmate 250  
Canvas Covers  
Within the warranty periods listed below, Miller will repair or  
replace any warranted parts or components that fail due to  
such defects in material or workmanship. Miller must be  
notified in writing within thirty (30) days of such defect or  
failure, at which time Miller will provide instructions on the  
warranty claim procedures to be followed.  
Your distributor also gives  
you ...  
Millers True Blue Limited Warranty shall not apply to:  
1. Consumable components; such as contact tips,  
cutting nozzles, contactors, brushes, slip rings,  
relays or parts that fail due to normal wear.  
Service  
You always get the fast,  
reliable response you  
need. Most replacement  
parts can be in your  
hands in 24 hours.  
Miller shall honor warranty claims on warranted equipment  
listed below in the event of such a failure within the warranty  
time periods. All warranty time periods start on the date that  
the equipment was delivered to the original retail purchaser, or  
one year after the equipment is sent to a North American  
distributor or eighteen months after the equipment is sent to an  
International distributor.  
2. Items furnished by Miller, but manufactured by others,  
such as engines or trade accessories. These items are  
covered by the manufacturers warranty, if any.  
Support  
3. Equipment that has been modified by any party other  
than Miller, or equipment that has been improperly  
installed, improperly operated or misused based upon  
industry standards, or equipment which has not had  
reasonable and necessary maintenance, or equipment  
which has been used for operation outside of the  
specifications for the equipment.  
Need fast answers to the  
tough welding questions?  
Contact your distributor.  
The expertise of the  
distributor and Miller is  
there to help you, every  
step of the way.  
1. 5 Years Parts 3 Years Labor  
*
*
Original main power rectifiers  
Inverters (input and output rectifiers only)  
MILLER PRODUCTS ARE INTENDED FOR PURCHASE  
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND  
PERSONS TRAINED AND EXPERIENCED IN THE USE  
AND MAINTENANCE OF WELDING EQUIPMENT.  
2. 3 Years Parts and Labor  
*
*
*
*
*
*
Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Supplies  
In the event of a warranty claim covered by this warranty, the  
exclusive remedies shall be, at Millers option: (1) repair; or (2)  
replacement; 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 customers risk and expense. Millers option of repair or  
replacement will be F.O.B., Factory at Appleton, Wisconsin, or  
F.O.B. at a Miller authorized service facility as determined by  
Miller. Therefore no compensation or reimbursement for  
transportation costs of any kind will be allowed.  
Intellitig  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by  
the engine manufacturer.)  
3. 1 Year Parts and Labor  
*
*
DS-2 Wire Feeder  
Motor Driven Guns (w/exception of Spoolmate  
185 & Spoolmate 250)  
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES  
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE  
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR  
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR  
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF  
PROFIT), WHETHER BASED ON CONTRACT, TORT OR  
ANY OTHER LEGAL THEORY.  
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
Induction Heating Power Sources  
Water Coolant Systems  
HF Units  
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN  
AND ANY IMPLIED WARRANTY, GUARANTY OR  
REPRESENTATION AS TO PERFORMANCE, AND ANY  
REMEDY FOR BREACH OF CONTRACT TORT OR ANY  
OTHER LEGAL THEORY WHICH, BUT FOR THIS  
Grids  
Maxstar 140  
PROVISION,  
MIGHT  
ARISE  
BY  
IMPLICATION,  
Spot Welders  
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE  
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF  
MERCHANTABILITY OR FITNESS FOR PARTICULAR  
PURPOSE, WITH RESPECT TO ANY AND ALL  
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND  
DISCLAIMED BY MILLER.  
Load Banks  
Miller Cyclomatic Equipment  
Running Gear/Trailers  
Plasma Cutting Torches (except APT & SAF  
Models)  
Some states in the U.S.A. do not allow limitations of how long  
an implied warranty lasts, or the exclusion of incidental,  
indirect, special or consequential damages, so the above  
limitation or exclusion may not apply to you. This warranty  
provides specific legal rights, and other rights may be  
available, but may vary from state to state.  
*
Field Options  
(NOTE: Field options are covered under True  
Blue for the remaining warranty period of the  
product they are installed in, or for a minimum of  
one year whichever is greater.)  
In Canada, legislation in some provinces provides for certain  
additional warranties or remedies other than as stated herein,  
and to the extent that they may not be waived, the limitations  
and exclusions set out above may not apply. This Limited  
Warranty provides specific legal rights, and other rights may  
be available, but may vary from province to province.  
4. 6 Months Batteries  
5. 90 Days Parts  
*
*
MIG Guns/TIG Torches  
Induction Heating Coils and Blankets  
miller_warr 7/00  
 
Owners Record  
Please complete and retain with your personal records.  
Model Name  
Purchase Date  
Distributor  
Address  
Serial/Style Number  
(Date which equipment was delivered to original customer.)  
City  
State  
Zip  
For Service  
to locate a DISTRIBUTOR or SERVICE AGENCY near you.  
Always provide Model Name and Serial/Style Number.  
Contact your Distributor for:  
Welding Supplies and Consumables  
Options and Accessories  
Personal Safety Equipment  
Service and Repair  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
Replacement Parts  
Training (Schools, Videos, Books)  
International HeadquartersUSA  
USA Phone: 920-735-4505 Auto-Attended  
USA & Canada FAX: 920-735-4134  
International FAX: 920-735-4125  
Technical Manuals (Servicing Information  
and Parts)  
Circuit Diagrams  
European Headquarters –  
United Kingdom  
Phone: 44 (0) 1204-593493  
FAX: 44 (0) 1204-598066  
Welding Process Handbooks  
www.MillerWelds.com  
Contact the Delivering Carrier for:  
File a claim for loss or damage during  
shipment.  
For assistance in filing or settling claims,  
contact your distributor and/or equipment  
manufacturers Transportation Department.  
PRINTED IN USA  
2000 Miller Electric Mfg. Co. 6/00  
 

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