Miller JA000000 Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
April
1995
Form:
OM-1521G
OWNERS
MANUAL
Guns
For
Automated
Applications
Read
and
follow
these
instructions
safety
blocks
carefully.
Have
only
trained
and
qualified
install,
operate,
or
service
this
unit.
and
all
persons
U
Give
this
manual
to
the
operator.
For
help,
call
your
distributor
U
Call
your
distributor
if
you
do
not
understand
I~I
U
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
the
directions.
Appleton,
WI
54912
414-734-9821
GA-30A:
Air-Cooled
GMAW
Gun,
300
Amperes
At
100%
Duty
Cycle
GA-30A1:
Air-Cooled
GMAW
Gun,
300
Amperes
At
100%
Duty
Cycle
GA-40A:
Air-Cooled
GMAW
Gun,
400
Amperes
At
100%
Duty
Cycle
GA-50A:
Air-Cooled
GMAW
Gun,
500
Amperes
At
100%
Duty
Cycle
GA-5OCA:
Air-Cooled
GMAW
Gun,
500
Amperes
At
100%
Duty
Cycle
GW-60A:
Water-Cooled
GMAW
Gun,
600
Amps
At
100%
Duty
Cycle
GA-8OAC1:
Air-Cooled
SAW
Gun,
800
Amperes
At
100%
Duty
Cycle
cover
1/94
'
1995
MILLER
Electric
Mig.
Co.
PRINTED
IN
USA
F
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
werranties
end
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
end
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appteton,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipmenl
sold
after
the
effective
date
ot
this
limited
warmnty
Is
tree
of
de
tects
in
material
aid
workmanship
at
the
time
It
is
shipped
by
MtLLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
tMPLtED,
INCLuDiNG
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warrantj
periods
listed
below,
MILLER
will
repair
or
replace
any
war
mnted
parts
orcomponents
that
tail
due
to
such
defects
in
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
auch
detect
or
failure,
at
which
time
MILLEF:
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
All
warranty
lime
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
lnternstional
distributor.
S
Years
Partr.
3
Years
Labor
Original
main
power
rectifiers
2.
3
Years
Parts
and
Labor
Transformer/Rectifier
Power
Sources
*
Plasma
Arc
Cuffing
Power
Sources
*
Semi-A
itomatic
and
Automatic
Wire
Feeders
Robots
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
1
Year
Parts
and
Labor
*
Motor
Driven
Guns
-
Proces,
Controllers
Water
Coolant
Systems
HP
Units
Grids
Spot
taeldem
Load
Banks
*
SDX
Tiansformers
*
Running
Gear/Trailers
*
Plasmr:
Cufting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
*
Tecumaeh
Engines
Deutz
Engines
(outside
North
America)
*
Field
Options
-
-
(NOTE:
Field
options
are
covered
under
True
eiueTM
for
the
remaining
warranly
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year
whichever
ix
greater.)
6
Months
Bafteries
Remote
Controls
Accessory
Kits
Replacement
Parts
MILLERS
True
BIueTM
Limited
Warranty
shall
not
eppfy
to:
1.
Items
furnished
by
MILLER,
but
manufactured
by
others,
such
ax
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
If
any.
2.
Consumable
components;
such
as
contact
tips,
cufting
nozztes,
contscfors
and
relays
or
parts
that
tail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperfy
installed.
improparfy
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.
MILLER
PRODUCTS
ARE
tNTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CtAL/INDUSTFfIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
iN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
af
MILLERS
option:
(1)
repair;
or
(2)
replacement;
or,
where
authorized
In
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
uae)
upon
return
of
Iha
goods
at
customers
risk
snd
expanse.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be
allowed.
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
CON
TRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
f
N
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EOUtPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
nol
atlow
timifafions
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
spe
cific
legaf
rights,
and
other
rights
may
be
avaifabla,
but
may
vary
from
state
to state.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
ax
stated
herein,
and
to
the
extant
thaI
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
J~,\vary
from
province
to
province.
I
S.
6.
g~
Days
arts
and
Labor
*
M1G
Gins/TIG
Torches
APT
ZIPCUT
&
PLAZCUT
Model
Plasma
Cuffing
Torches
I
r......
RECEIVtNG-HANDLING
Before
Unpack
ng
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
Shipment.
File
any
claims
for
loss
or
damage
with
the
deliv8ring
carrier,
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit,
The
information
is
located
on
the
rating
label
or
nameplate.
Model
Serial
or
Style
No.
______________________________________________
Date
of
Purchase
miller
1/95
SAFETY
PRECAUTIONS
FOR
GMAW
GUNS
ELECTRIC
SHOCK
can
kill.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Do
not
touch
live
electrode
or
electrical
parts.
Repair
or
replace
worn,
damaged,
or
cracked
gun
or
cable
insulation.
5.
Turn
off
welding
power
source
before
changing
contact
tip
or
gun
parts.
6.
Keep
all
covers
and
handle
securely
in
place.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
1.
Keep
your
head
out
of
the
fumes.
2.
Ventilate
area,
or
use
breathing
device.
3.
Read
Material
Safety
Data
Sheets
(MSDSs)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Do
not
weld
on
closed
containers.
Watch
for
fire;
keep
extinguisher
nearby.
ARC
RAYS
can
burn
eyes
and
skin.
1.
Wearwelding
helmetwith
correct
shade
of
filter.
2.
Wear
correct
eye
and
body
protection.
3.
Cover
exposed
skin
with
spatter-resistant
clothing.
j
HO
1.
T
SURFACES
can
burn
skin.
Allow
gun
to
cool
before
touching.
?i~!
,
2.
3.
Do
not
touch
hot metal.
Protect
hot
metal
from
contact
by
others.
NOISE
can
damage
hearing;
SOME
APPLICATIONS,
SUCH
AS
PULSING,
are
noisy.
1.
Check
for
noise
level
limits
exceeding
those
specified
by
OSHA.
2.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
3.
Warn
others
nearby
about
noise
hazard.
WELDING
WIRE
can
cause
puncture
wounds.
1.
Keep
hands
and
body
away
from
gun
tip
when
trigger
is
pressed.
EMF
INFORMATION
WARNING
PROTECT
YOUI~SELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
GMAW
WELDING
can
be
hazardous.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
informatioii
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
wire
feeder
and
welding
power
source
Owners
Manuals.
Read
and
follow
all
safety
precautions.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
lED
PEoPLE.
1.
2.
3.
4.
1.
2.
3,
NOTEL~
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
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
Backg
round
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printir.g
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
quaIit~,
the
results
are
complex.
Current
scientific
understanding
doe~
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.
modlO
1
4/93
sr7
7/93
SECTION
1
-
SAFETY
INFORMATION
modl.1
2/93
6
Obey
all
safety
messages
to
avoid
injury.
a
W~RNING
~
a
CAUTION
U
Read
all
safety
messages
throughout
this
manual.
U
Learn
the
meaning
of
WARNING
and
CAUTION.
1
2
ELECTRIC
SHOCK
can
kill
Do
not
touch
live
electrical
parts.
Dis~onnect
input
power
beforejJ
~
installing
or
servicing.
5
2
\
MOVING
PARTS
can
Injure,
I
Keep
away
from
moving
parts.
I
Keep
all
panels
and
covers
closed
I
when
operating.
I
1
Safety
Alert
Symbol
2
Signal
Word
or
serious
injury
can
happen.
WARNING
means
possible
death
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard
And
Result
4
Safety
Instructions
To
Avoid
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
Special
instructions
for
best
oper
ation
not
related
to
safety.
READ
SAFETY
BLOCKS
at
start
of
I
Section
3-1
before
proceeding.
7H
NOTE
~
Turn
Off
switch
wh
en
using
high
frequency
Figure
1-1.
Safety
Information
SECTION
2-SPECIFICATIONS
Table
2-1.
Welding
Guns
Model
Rating:
100%
Duty
Cycle
DCEP
Wire
Diameter
Capacity
Cooling
Method
Weight
Net
Ship
GA-30A
GA-30A1
300
Amperes
With
CO2
200
Amperes
With
Argon
.030,
.035,
.045
in
(0.8,
0.9,
1.1
mm)
Hard
Wire
.030,
.035,
3/64,
1/16
in
(0.8,
0.9,
1.2,
1.6
mm)
Soft
Wire
Air
20
oz
(567
g)
38
oz
(1077
g)
GA-40A
400
Amperes
With
CO2
.035,
.045,
1/16
in
(0.9,
1.1,
1.6
mm)
Hard
Wire
Air
21
oz
(595
g)
40
oz
(1134
g)
GA-50A
500
Amperes
With
CO2
.035,
.045,
.052,
1/16,
5/64,
3/32, 7/64,
1/8
in
(0.9,
1.1,
1.3,
1.6,
2.0,
2.4,
2.8,
3.2
mm)
Hard
Wire
Air
35
oz
(992
g)
55
oz
(1559
g)
GA-5OCA
51)0
Amperes
With
CO2
.045,
.052,
1/16,
5/64, 3/32,
7/64,
1/8,
in
(1.1,
1.3, 1.6,
2,0,
2.4,
2.8,
3.2
mm)
Hard
Or
Cored
Wires
Air
29
oz
(822
g)
37
oz
(1049
g)
GW-60A
6)0
Amperes
With
CO2
500
Amperes
With
Argon
.035,
3/64,
1/16,
3/32
in
(0.9,
1.2,
1.6,
2.4
mm)
Soft
Wire
.035, .045, .052,
1/16,
5/64,
3/32,
7/64,
1/8
in
(0.9,
1.1,
1.3,
1.6,
2.0,
2.4,
2.8,
3.2
mm)
Hard
Wire
Water
42
oz
(1191
g)
62
oz
(1758
g)
GA-8OAC1
800
Amperes
SLbmerged
Arc
1/16,
5/64,
3/32,
7/64,
1/8,
5/32,
3/16
in
(1.6,2.0,
2.4,
2.8,
3.2,
4.0,4.8
mm)
Hard
Wire
Air
37
OZ
(1048
g)
6002
(1701
g)
OM-1521
Page
1
15-1/16
in
(383
mm)
With
Optional
Head
Tube
Extension
GW-60A
Models
5/8
in
Diameter
(15.9mm)
1-3/16
In
(30.2
mm)
1-5/16
In
(33.3
mm)
1-1/4
in
SA-080
847-A
5/16
in
(7.9
mm)
9/16
in
(14.3mm)
SA-080
846-A
GA-40A
Models
bin
(127mm)
*13
in
(330.2
mm)
For
GA-30A1
GA-30A
And
GA-30A1
Models
SA-097
632-A
13~>~
(330.2
mm)
SA-049
239-B
*17.5/8
In
(447.7
mm)
With
Optional
Head
Tube
Extension
GA-50A
Models
SA-049
258-C
1-3/16
in
(30.2
mm)
4
In
(101.6mm)
GA-5OCA
Models
SB-088
002-A
1-15/16
In
(33.3
mm)
GA-8OAC1
Models
Figure
2-1.
Overall
Dimensions
OM-1521
Page
2
SECTION
3-INSTALLATION
WARNING
ELECTRIC
SHOCK
can
kill.
Dci
not
touch
live
electrical
parts.
Turn
Off
weld
control
and
welding
power
source,
and
disconnect
input
power
before
inspecting
or
in~talIing.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire.
Have
only
qualified
persons
install
this
unit
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
WELDING
WIRE
can
cause
puncture
wounds.
Keep
hands
away
from
gun
tip
when
wire
drive
is
energized.
Do
not
try
to
feed
wire
until
instructed
to
do
so
in
wire
drive
Owners
Manual.
H
S
OT
SURFA
Allow
drive
CES
ca
assembly
n
bu
and
rn
skin.
gun
to
cool
before
touching.
4
NOTE
I~
For
installation
to
wire
drive
assembly,
see
wire
drive
Owners
Manual.
3-1.
Shielding
Gas
Nozzle
Adjustment
.
1
2
1
Nozzle
Extension
Jam
Nut
2
Nozzle
Extension
Loosen
jam
nut,
twist
nozzle
exten
sion
to
allow
desired
contact
tube
stick
out,
and
tighten
nut.
Ref.
ST-080
847-A
Figure
3-1.
GA-30A
And
GA-30A1
Adjustment
.
1
Securing
Nut
2
Shielding
Gas
Tube
Loosen
nut,
position
tube,
and
tighten
nut.
2
Ref.
ST-080
846-A
Figure
3-2.
GA-40A
Adjustment
OM-1521
Page
3
3-2.
Flux
Tube
Adjustment
1
2
WARNING
x
Figure
4-1.
Safety
Equipment
NOTE
~
As
a
starting
point,
position
contact
tube.
Increase
or
flashthroughs
do
not
occur.
nozzle
so
t
decrease
hat
b
flux
ottom
o
depth
I
nozzle
is
flush
to
a
point
just
with
end
of
where
arc
1
Nozzle
Mounting
Nut
2
Nozzle
Extension
Loosen
nut,
twist
or
slide
extension
to
desired
positi
nozzle
on,
and
tighten
nut.
Ref.
ST-049
258.c
Figure
3-3.
Flu
x
T
ube
Adjustment
SECTION
4
-
OPERATION
Do
not
touch
live
electrical
parts.
ELECTRIC
SHOCK
can
kill.
,
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
NOISE
can
damage
hearing.
ARC
RAYS
can
burn
eyes
and
skin;
S
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDSs)
and
manufacturers
instructions
for
material
used.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
S
Keep
away
from
pinch
points
such
as
drive
rolls.
.
~~-
RENTS
can
affect
pacemaker
operation.
MAGNETIC
FIELDS
FROM
HIGH
CUR
S
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor before
going
near
any
welding
operations.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
~arn3
r
8/92
Allow
work
and
equipment
to
cool
before
handling,
1
~
2
~
3
/
~
W
1
2
3
ear
the
following
while
welding:
Dry,
Insulating
Gloves
Safety
Glasses
With
Side
Shields
Welding
Helmet
With
Correct
Shade
Of
Filter
(See
ANSI
Z49.
1)
sb3.1
1/94
OM-1521
Page
4
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Miller JA000000 Owner's manual

Category
Welding System
Type
Owner's manual
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