Professional Documents
Culture Documents
Processes
Automatic Welding
Description
Wire Feeder
Mil_Thank 2009−09
TABLE OF CONTENTS
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Council Directives:
• 2014/35/EU Low Voltage
• 2014/30/EU Electromagnetic Compatibility
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 60974-5:2013 Arc welding equipment – Part 5: Wire feeders
• IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
_____________________________________ ___________________________________________
David A. Werba Date of Declaration
243050D
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
D Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information D When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord and ground conductor for
repair this unit. damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
During operation, keep everybody, especially children, away. D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill.
D If earth grounding of the workpiece is required, ground it directly
Touching live electrical parts can cause fatal shocks with a separate cable.
or severe burns. The electrode and work circuit is D Do not touch electrode if you are in contact with the work, ground,
electrically live whenever the output is on. The input or another electrode from a different machine.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic D Do not touch electrode holders connected to two welding ma-
wire welding, the wire, wire reel, drive roll housing, chines at the same time since double open-circuit voltage will be
and all metal parts touching the welding wire are present.
electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts. D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats D Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground. D Insulate work clamp when not connected to workpiece to prevent
D Do not use AC output in damp areas, if movement is confined, or if contact with any metal object.
there is a danger of falling. D Do not connect more than one electrode or work cable to any
D Use AC output ONLY if required for the welding process. single weld output terminal. Disconnect cable for process not in
use.
D If AC output is required, use remote output control if present on
unit. D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
D Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
SIGNIFICANT DC VOLTAGE exists in inverter weld-
as floors, gratings, or scaffolds; when in cramped positions such ing power sources AFTER removal of input power.
as sitting, kneeling, or lying; or when there is a high risk of unavoid- D Turn Off inverter, disconnect input power, and discharge input
able or accidental contact with the workpiece or ground. For these capacitors according to instructions in Maintenance Section
conditions, use the following equipment in order presented: 1) a before touching any parts.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder HOT PARTS can burn.
is recommended. And, do not work alone!
D Do not touch hot parts bare handed.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to D Allow cooling period before working on
OSHA 29 CFR 1910.147 (see Safety Standards). equipment.
D Properly install, ground, and operate this equipment according to D To handle hot parts, use proper tools and/or wear heavy, insu-
its Owner’s Manual and national, state, and local codes. lated welding gloves and clothing to prevent burns.
OM-242671 Page 1
D Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
D Keep your head out of the fumes. Do not breathe the fumes. D Remove any combustibles, such as a butane lighter or matches,
D If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way D After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator. pass them.
D Read and understand the Safety Data Sheets (SDSs) and the D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. D Read and understand the Safety Data Sheets (SDSs) and the
D Work in a confined space only if it is well ventilated, or while manufacturer’s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
D Do not weld on coated metals, such as galvanized, lead, or D Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and D Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). D Implanted Medical Device wearers should consult their doctor
D Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
D Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
D Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.
OM-242671 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
OM-242671 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2012−05
Safe30 2012−05
Gas Input
A Amperes V Volts
Direct Current
(DC)
IP Degree Of
Protection U1 Primary Voltage I1 Primary Current I2 Rated Welding
Current
OM-242671 Page 9
SECTION 4 − SPECIFICATIONS
4-1. Unit Specifications
Wire Feed Wire Diameter Type Of Input Weight
Model Input Power Cord
Speed Range Range Power Net Ship
50 To 1400 ipm .023 To 1/8 in. 16-1/2 lb 17-1/2 lb
AA40GB 40 VDC, 10 A 2 ft (0.6 m)
(1.3 To 35.6 mpm) (0.6 To 1.3/1.4 mm) (7.5 kg) (7.9 kg)
! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances. ce-emc 3 2014-07
Notes
OM-242671 Page 10
4-3. Overall Dimensions And Mounting Hole Layout
Inches Millimeters Inches Millimeters
A 9-3/4 248 A 3-1/4 83
C
B
Inches Millimeters
A 7 178
B 3-1/2 89
C
C 3-1/4 83
D D 6 152
E 5-1/2 140
F 1-1/2 38
Adapter Bracket
OM-242671 Page 11
SECTION 5 − INSTALLATION
5-1. Typical Equipment Location
5
4
6
3
2
Tools Needed:
3/16 in.
OM-242671 Page 12
5-3. Motor Mounting And Gun, Weld Cable, And Gas Connections
. Drive motor must be isolated
from weld potential.
1 Insulator Plate
When mounting motor, place
factory-supplied insulator plate
under motor mounting bracket to
provide isolation.
2 Customer Supplied Gas Hose
3 Shielding Gas Valve Fitting
Requires hose fitting with 5/8-18
right-hand threads.
For guns requiring external gas
connections, remove hose from
barbed fitting near gun/feeder
opening and connect to gun.
4 Gun/Feeder Securing Knob
5 Gun/Feeder Opening
6 Gun End
Loosen knob. Insert gun end into
opening. Position as close as pos-
1
sible to drive rolls without touching.
Tighten knob. See Section 5-4.
7 Weld Cable Terminal
8 Weld Cable
Select and prepare weld cable ac-
cording to welding power source
Owner’s Manual.
3 2
4 For guns with external weld cable,
connect weld cable from gun to ter-
minal.
Tools Needed:
OM-242671 Page 13
5-4. Installing Welding Gun
1 Gun Locking Tab
2 Power Clamp Knob
3 Gun Connection End
4 Power Pin Groove
Installing gun with Accu-Mate
connection
Loosen power clamp knob to allow
power pin of gun to clear the gun
locking tab.
Push power pin into power clamp
as far as possible to align the
groove in the power pin of the gun
with the gun locking tab.
Secure gun by tightening power
clamp knob.
Installing gun without Accu-
Mate connection
When using a gun without the
groove in the power pin, loosen
power clamp knob and rotate gun
locking tab 180 degrees. This pre-
vents the locking tab from extend-
ing into the power pin gun connec-
tion.
Push power pin into power clamp
as far as possible.
Secure gun by tightening power
4
clamp knob.
3
2 2
1 1
OM-242671 Page 14
5-5. Plug Connections
1 Weld Control
2 Motor Control Cord (Not
Supplied)
Cord is available in 20 ft (6.1 m),
30 ft (9.1 m) or 50 ft (15.2 m)
lengths.
3 Motor/Drive Assembly
To make connections, align key-
way, insert plug, and tighten
threaded collar.
804 104-C
OM-242671 Page 15
5-6. Threading And Feeding Welding Wire
Tools Needed:
ON
PURGE
V
OFF
POWER JOG 6 in.
(150 mm)
Turn on power at welding power source. Pull and hold wire; cut off end.
Pressure Pressure
Adjust Adjust
JOG
WOOD
Push wire thru guide up to drive rolls; continue to Press Jog push button until wire comes Cut off wire. Close cover.
hold welding wire. Press power source Jog push out of gun. Feed wire to check drive roll
button until drive rolls grab wire. Adjust tension until pressure. Adjust knob enough to pre-
wire does not slip. Indicator is for reference only. vent slipping.
OM-242671 Page 16
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
3 Months
6 Months
OR
Replace
Tools Needed:
Damaged
Brushes
Ref. 137 390-C / S-0816
OM-242671 Page 17
6-3. Troubleshooting
Trouble Remedy
Electrode wire feeding stops or feeds er- Readjust hub tension and drive roll pressure.
ratically during welding.
Change to correct size drive roll.
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around gun nozzle opening.
Check and secure motor plug connection.
Have Factory Authorized Service Agent check drive motor.
Motor runs slowly. Reduce load.
Check for correct input voltage.
Motor runs at full speed regardless of Have Factory Authorized Service Agent check digital wire drive motor Tachometer board and encoder.
wire speed setting.
221 660-B
OM-242671 Page 19
SECTION 8 − PARTS LIST
17
6 25
7
5 57
55 10
56 14
8 9 13
4 12
3 11 64
2 63 57
1 59 58
60
49
3 41
2 52
1
30 50
26
27 53
39
28
40
34 4
3 55
29 2 6 62
35 5
7 56
36 1 51
37 33 3
38 2 61
42 43 1 54
32 46
31
45
44
48
47
804 105-K
OM-242671 Page 22
SHELLED CORED WIRE GUIDES
WIRES
WIRE SIZE
.023/.025 in. (0.6 mm) 151024
.030 in. (0.8 mm) 151025
.035 in. (0.9 mm) 151026 151052 243233
.040 in. (1.0 mm) 161190
.045 in. (1.1/1.2 mm) 151027 151037* 151053 151070 243234*
.052 in. (1.3/1.4 mm) 151028 151038 151054 151071
1/16 in. (1.6 mm) 151029 151039 151055 151072 243235
.068/.072 in. (1.8 mm) 151056
5/64 in. (2.0 mm) 151040 151057 151073
3/32 in. (2.4 mm) 151041 151058 151074
7/64 in. (2.8 mm) 151042 151059 151075
1/8 in. (3.2 mm) 151043** 151060** 151076**
Table 8-1. Drive Roll And Wire Guide Kits
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01