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OM-227 674B 2006 −08
Processes
Automatic Welding
Description
Wire Feeder
AA40GBU
File: Advanced Manufacturing Systems
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Insta
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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SECTION 3 − INSTALLATION 3-1. Specifications Weight Wire Feed Wire Feed Model Model Wire Diameter Range Wire Diameter Range T Type ype Of Input Power Of Input Power Speed Range Net Ship 50 To 1400 ipm .045 To .062 in 16-1/2 lb 21-1/2 lb AA40GBU 40 VDC, 10 A (1.3 To 35.6 mpm) (1.1 To 1.6 mm) (7.5 kg) (9.8 kg) 3-2. Overall Dimensions And Mounting Hole Layout Inches Millimeters Inches Millimeters A 8 203 A 3-1/4 83 B 12-1/2 318 B 3-1/2 89 C 9-1/2 241 C 3/8 Dia. 9.5 Dia. 4 Holes 4 Holes C A B B A C
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3-3. Typical Equipment Location 5 4 6 3 2 1 7 1 Welding Power Source 4 Weld Control 6 Wire Drive Assembly 2 Gas Cylinder 5 Spool Support 7 Automatic Welding Gun 3 Side Beam ST-131 138-A 3-4. Installing Drive Rolls 1 Pressure Assembly Door 2 Drive Roll 3 Ejector Button 4 Drive Roll Carrier Installation 4 Open pressure assembly door. 3 Align drive roll slots with three lobes on drive roll carrier. Insert drive roll onto carrier. Drive roll will snap into place. Removal Remove PD wire guide befor
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3-5. Installing PD Continuous Wire Guides PD Continuous Wire Guides: Should be used with .068/.072 in (1.8 mm) and smaller diameter wire for opti- mal performance. Should be used with PD drive rolls and cannot be used with non-PD (old-style) drive rolls. 70 series wire guides are not compatible with 75 series wire 3 feeders. 1 Pressure Assembly Door 2 PD Inlet Guide 3 PD Wire Guide (Hard Wire) 4 PD Wire Guide (Two Pieces interlocked for Aluminum 4 Wire) Installing PD continuous wire guides w
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3-6. Installing Non-PD (Old Style) Wire Guides Installing wire guides with non- PD (old-style) drive rolls Non-PD (old-style) wire guides and drive rolls should be used with 5/64 in (2.0 mm) and larger diameter wire. 1 Pressure Assembly Door 2 PD Inlet Guide 3 Intermediate Guide 5 4 Set Screw 2 5 Guide Holder 6 Exit Guide 6 3 Open pressure assembly door. Lift up drive roll swing arms. 4 Install PD inlet guide. Do not tighten set screw to se- cure inlet guide. Set screw may be used to se- c
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3-7. Installing Welding Gun 1 Power Clamp Knob 2 Gun Locking Tab 3 Power Pin Groove 4 Gun Connection End Installing gun with Accu-Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab. When installing gun, the liner should extend into the PD continu- ous guide (or exit guide if used) as far as possible without interfering with the guide. Align the groove in the power pin of the gun with the gun locking tab. Secure gun by tightening power 4 clamp knob. Ins
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3-8. Mounting Motor And Connecting Gas Hose And Weld Cable 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. 4 Weld Cable 5 Weld Cable Screw - Screw Size (.375 − 16 X 1.50) Select and prepare weld cable ac- cording to welding power source Owner’s Manual. F
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3-9. Plug Connections 1 Weld Control 2 Motor Control Cord (Not Supplied) 1 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. 2 3 804 592-A OM-227 674 Page 15
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3-10. Threading Welding Wire And Adjusting Pressure Drive Setting Tools Needed: Hold wire tightly to keep it from unraveling. Welding Power Source ON PURGE V OFF JOG POWER 6 in (150 mm) Turn on power at welding power source. Pull and hold wire; cut off end. Adjust tension. 2 1 Drive Rolls Pressure assembly door not shown. Back Of Gun Cable End Of Liner No Wire Slip Wire Slips NONCONDUCTIVE NONCONDUCTIVE SURFACE SURFACE Ref. 804 391-A / Ref. 804 190-A / Ref. 156 798 1 Drive Roll Pressure Adjust
