Miller A1-2 Owner's manual

Brand: Miller

Model: A1-2

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Millerﬁ

March

1

993

Form:

OM-1538B

Effective

With

Style

No.

JD-3

OWN

ERS

MANUAL

Al

Motor/Drive

Assemblies



Read

and

follow

these

instructions

and

all

safety

blocks

carefully.



Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.



Call

your

distributorif

you

do

not

understand

the

directions.



115

Volts

DC

Motor

And

Wire

Drive

Assembly



For

Automatic

Weld

Control

Or

Arc

Welding

Robot



For

GMAW,

FCAW

And

SAW

Welding



Two-

And

Four-Drive

Roll

Models

Available

U

Adjustable

Mounting

Bracket

(Not

Availabte

On

Robotic

Model)



Low

Speed

Motor

Available



Interconnecting

Cord

To

Weld

Control

Needed

U

Give

this

manual

to

the

operator.



For

help,

call

your

distributor



or:

MILLER

ELECTRIC

Mfg.

Co.,

P.O.

Box

1079.

Appleton,

WI

54912

414-734-9821

cover

0/92

-

ST-070

8a5-B

PRINTED

IN

USA

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supersedes

alt

previous

MILLER

warranties

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..

Appleton.

Wisconsin.

warrants

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

of

this

limited

warranty

is

free

of

de

fects

in

material

and

workmanship

at

(Pie

time

It

Is

shIpped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTtES.

EXPRESS

OR

IMPLIED.

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below.

MILLER

will

repair

or

replace

any

war

ranted

parts

or

components

that

tall

due

to

such

defects

In

material

or

worlimsnshlp.

MILLER

must

be

notified

In

writing

within

thirty

(30)

days

of

such

defect

or

failure,

at

which

lime

MILLER

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

lime

periods.

All

warranty

time

periods

start

on

the

dale

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

and

are

as

follows:

t.

5

Years

Parts

3

Years

Labor

Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor

Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders



Robots

3.

2

Years



Parts

end

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer)

4.

1

Year



Parts

and

Labor



Motor

Driven

Guns



Process

Controllers



Water

Coolant

Systems



HF

Units

Grids



Spot

Welders



Load

Banks



SDX

Transformers



Running

Gear/Trailers



Field

Options

(NOTE

Field

options

are

covered

under

True

BIue

for

the

remaining

warranty

period

of

the

product

they

are

installed

in.

or

for

a

minimum

of

one

year



whichever

is

greater.)

5.

6

Months



Batteries

6.

90

Days



Parts

and

Labor



MIG

Guns/TIG

Torches



Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits

Replacement

Parts

MILLERS

True

OluerM

Limited

Warranty

shall

not

apply

to:

1.

Items

furnished

by

MILLER.

but

manufactured

by

others,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components;

Such

55

contact

tips,

cutting

nozzles.

coritactors

and

relays.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER.

or

equip

ment

that

has

bean

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.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT.

In

the

event

ot

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be,

at

MILLERS

option:

(I)

repair:

or

(2)

replacement;

or,

where

authorized

In

writing

by

MILLER

in

appropriate

cases.

(3)

the

reasonable

Cost

of

repair

or

replace.

mental

an

authorized

MILLER

service

station;

or

(4)

payment

of

or

credit

for

the

pur

chase

price

(tess

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton.

Wisconsin.

or

F.O.B.

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.

IN.

CLUDING

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.

Some

stales

in

the

U.S.A.

do

not

allow

limitalions

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequenlial

damages,

so

the

above

limitation

or

esciusion

may

not

apply

to

you.

This

warranty

provides

spe

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

Irom

state

to

state.

In

Canada.

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

staled

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

set

Oul

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

province

10

province.

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

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

5/92

ERRATA

SHEET

January

12,

1994

FORM:

OM-1538B

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANGES

TO

SECTION

3-

INSTALLATION

Replace

Figure

3-4.

Installing

Wire

Guide

And

Drive

Roil

(Four-Drive

Roll

ModeI.Shown)

Figure

3-4.

Installing

Wire

Guide

And

Drive

Roll

(Four-Drive

Roil

Model

Shown)

CHANGES

TO

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

Add

the

following

Caution

for

Four-Drive

Roll

Model

to

Section

5-2.

Aligning

Drive

Rolls

And

Wire

Guides

£~

CAUTION

IMPROPER

CLEARANCE

between

motor

gear

and

drive

gears

can

damage

equipment.



Maintain

0.003

in

(0.076

mm)

clearance

between

motor

gear

and

drive

gears.

Gears

may

wear

severely,

bind,

break,

or

cause

erratic

wire

feed

if

proper

clearance

Is

not

maintained.

When

changing

wire

size

or

type,

check

drive

roll

and

guide

size

(see

Table

6.1

and

Table

6-2).

1

Wire

Guide

Securing

Screw

2

Inlet

Wire

Guide

3

Intermediate

Wire

Guide

(Four-Drive

Roll

Models

Only)

Loosen

wire

guide

screws.

Slide

tip

as

close

to

drive

rolls

as

possible

without

touching.

lighten

screw.

4

Drive

Gear

5

Pressure

Gear

Driveandpressuregears(1

of

each

In

two

drive

roll

model)

Installed

be

fore

unit

Is

shipped

from

factoiy.

6

Pressure

Gear

Assembly

Open

pressure

gear

assembly.

7

Drive

Roll

8

Gear

Securing

Bolt

9

Drive

Roll

Securing

Screw

Install

correct

drive

roll

for

wire

size

and

type

using

supplied

hardware.

Close

pressure

gear

assembly.

ST-070

887.E

Tools

Needed:

7/16

in

9

CHANGES

TO

SECTION

6

PARTS

LIST

Change

Parts

List

as

follows:

Part

Replaced

**

No.

With

Description

Quantity

13-3...

.

079 669

166

071

..

LEVER,

mtg

pressure

gear

(Effw/KE555371)

1

13-

Added

166

072

..

SPACER,

gear

(part

of

wire

drive

assembly)

(Eff

w/KE555371)

1

16-16

..

.

046

621

166

337

..

HOUSING,

adapter

gun/feeder

(Eff

w/KE555371)

1



16-21

..

.

079 669

166

071

..

LEVER,

mtg

pressure

gear

(Eff

W/KE555371)

1



16-24

..

.

046

619

166

338

..

LEVER,

mtg

pressure

gear

(Eff

w/KE555371)

1

16-

Added

166

072

..

SPACER,

gear

(part

of

wire

drive

assembly)

(Eff

w/KE555371)

1

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-1538B

Page

2

ARC

WELDING

SAFETY

PRECAUTIONS

WARNIN.G

ARC

WELDING

can

be

hazardous.

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

that

will

be

found

in

the

Safety

Standards

listed

on

the

next

page.

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

small

cracks

and

openings

to

adjacent

areas.

5.

Properly

install

and

ground

this

equipment

accrding

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

When

making

input

connections,

attach

proper

grounding

conductor

first.

7.

Turn

off

all

equipment

when

not

in

use.

8.

Do

not

use

worn,

damaged,

undersized,

or

poorly

splIced

cables.

9.

Do

not

wrap

cables

around

your

body.

10.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground..

11.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

12.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

13.

Wear

a

safety

harness

if

working

above

floor

level.

14.

Keep

all

panels

and

covers

securely

in

place.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

Do

not

use

welder

to

thaw

frozen

pipes.

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.



1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

2.

Wear

proper

body

protection

to

protect

skin.

ARC

RAYS

can

burn

eyes

and

skin;

~

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

-

-.

heat

and

strong

ultraviolet

rays

thai

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

.

NOISE

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

ARC

RAYS

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.

I

listed

in

Safety

Standards)

to

protect

your

facE,

and

eyes

when

welding

or

watching.

3.

Wear

approved

safety

glasses.

Side

shields

recommended.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare:

warn

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

can

be

hazardous

to

your

health,

1

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

4.

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

and

cleaners,

5.

6.

7.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

welding

can

displace

air

causing

lnfury

or

death.

Be

sure

the

breathing

air

is

safe.

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

if

welded.

WELDING

can

cause

fire

or

explosion.

Sparks

and

spatter

fly

off

from

the

welding

arc,

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece.

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

orwelding

wire

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

5.

6.

7.

8.

9.

10.

FLYING

SPARKS

AND

HOT

METAL

can

cause

Injury.

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

5r1

9/92

CYLINDERS

can

explode

if

damaged.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-I

listed

in

Safety

Standards.

a

WARNING~

ENGINES

can

be

hazardous.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.

explosion.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

3.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and add

Engine

fuel

is

highly

flammable.

fuel

to

cold

engine

before

beginning

job.

4.

Do

not

overfill

tank



allow

room

for fuel

to

expand.

5.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

MOVING

PARTS

can

cause

Injury.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATTERY

ACID

can

2.

Stop

engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

Batteries

contain

acid

and

generate

explosive

gases.

3.

4.

5.

cables.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

Observe

correct

polarity

(+

and

)

on

batteries.

fr.

~

(..~

~

-.

~

STEAM

AND

COOLANT

can

skin.

The

coolant

in

the

r

under

pressure.

PRESSURIZED

burn

face,

eyes,

adiator

can

be

very

h

HOT

and

ot

and

1.

2.

3.

Donotremoveradiatorcapwhenengineishot.Allowengine

to

cool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.

1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd.

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office.

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers That

Have

Held

Hazardous

Substances,

Amen.

can

Welding

Society

Standard

AWS

F4.

1,

from

American

Welding

So

ciety.

550

N.W.

LeJeune

Ad,

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association.

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i.

from

Compressed

Gas

Association.

1235

Jefferson

Davis

High.

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

GSA

Standard

WI

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Aexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

ForOccupationAnd

Educational

EyeAnd

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway.

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Ouincy,

MA

02269.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stop

engine

before

installing

or

connecting

unit.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

srI

9/92

TABLE

OF

CONTENTS

SECTION

1

-

SAFETY

INFORMATiON

1

SECTION

2

SPECIFICATIONS

1

SECTION

3

INSTALLATION

3-1.

Typical

Equipment

Location

3

3-2.

Installing

Pivot

Mounting

Bracket

3

3-3.

Removing

Vent

Screw

And

Mounting

Wire

Drive

Assembly

4

3-4.

Installing

Wire

Guide

And

Drive

Rolls

4

3-5.

Plug

Connections

5

3-6.

Gun,

Weld

Cable

And

Gas

Connections

6

3-7.

Threading

And

Feeding

Welding

Wire

7

SECTION

4

OPERATION

7

SECTION

5

MAINTENANCE

AND

TROUBLESHOOTING

5-1.

Routine

Maintenance

8

5-2.

Aligning

Drive

Rolls

And

Wire

Guides

9

5-3.

Brush

Inspection

And

Replacement

10

5-4.

Troubleshooting

11

SECTION

6PARTS

LIST

Figure

6-1.

Motor

&

Drive

Assembly

(Al

-2

Model

Illustrated)

12

Figure

6-2.

Motor

&

Drive

Assembly

15

OM.1538B-.3/93

SECTION

1



SAFETY

INFORMATION



modt.1

2/93

AA

CAUTION

U

Read

all

safety

messages

throughout

this

manual.

U

Obey

all

safety

messages

to

avoid

injury.

U

Learn

the

meaning

of

WARNING

and

CAUTION.

1

Safety

Alert

Symbol

1

2

2

2

Signal

Word

~

WARNING

means

possible

death

or

serious

injury

can

happen.

!~~L

:h1h~IeU

1

~

CAUTION

means

possible

minor

=9

ELECTRIC

SHOCK

can

kitl.f

~

MOVING

PARTS

can

Injure,

injury

or

equipment

damage

can

~\



Do

not

(Ouch

live

electrical

parts.



Keep

away

from

moving

parts.

happen.



Disconnect

input

power

before

S

Keep

all

panels

and

covers

dosed

3

Statement

Of

Hazard

And

installing

or

servicing,

when

operating.

Result

/

4

Safety

Instructions

To

Avoid

5

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

6_~__~L1_1.1IIj~

~

~

Read

safety

blocks

for

each

sym

7

NOTE

NOTE

~

Turn

Off

switch

when

using

high

frequency.

Special

instructions

for

best

oper

ation



not

related

to

safety.

FIgure

1-1.

Safety

Information

.

SECTION

2

SPECIFICATIONS



Table

2-1.

Wire

Drive

Assemblies

Specification

DescriptIon

Type

Of

Input

Power

115

Volts

DC

Mounting

Bracket

Adjustment

Up

To

200

In

Any

Direction

(Robotic

Model

Not

Adjustable)

Input

Power

Cord

(Two-Drive

Roil

Assemblies

Only)

2

ft

(0.6

m)

Overall

Dimensions

See

Figure

2-1

Options

See

Rear

Cover

Weight



Two-Drive

Roll

And

Robotic

Assemblies

18

lb

(7.9

kg)

Weight



Four-Drive

Roll

Assembly

Wire

Feed

Speed

Range

22

lb

(10

kg)

Standard

Digital

Or

Robotic

Low-Speed

Motor

Lo~~~Ior

7OTo

750

ipm

50

To

780

pm

20

To

190

ipm

15

To

200

ipm

(1.8

To

19.1

mpm)

(1.3

To

19.8

mpm)

(0.5

To

4.8

mpm)

(0.4

To

5.1

mprn)

Wire

Diameter

Range

.030

Thru

1/8

in

(0.8

Thru

3.2

mm)

.030

Thru

1/8

in

(0.8

Thru

3.2

mm)

5/64

Thru

5/32

in

(2

Thru

4

mm)

5/64

Thru

5/32

in

(2

Thru

4

mm)

OM-1538

Page

1

Nio-Drive

Roll

Models

Inches

Millimeters

A

8

C*

9-1/4

10-1/4

11-1/2

235

260

292

*Add

7/8

in

(22

mm)

for

D

models.

Four-Drive

Roll

Models

AID-4R

Inches

Millimeters

A

B

C*

10-1/4

13-1/4

12

260

337

305

*Add

7/8

in

(22

mm)

for

0

models.

/C

Mounting

Holes*

Inches

Millimeters

A

B

4-1/4

4-1/4

108

108

C

13/32Dia.

4

Holes

lODia.

4

Holes

Holes

shown

used

for

mounting

to

optional

cross

slide.

Additional

holes

provided

for

mounting

to

weld

oscillator.

ST-080

407-C

/

ST-076

085-B!

ST-lb

159-8

/

Rel.

5T-070

885-B

Figure

2-1.

Overall

Dimensions

And

Mounting

Hole

Layout

Inches

Millimeters

.;

7-3/4

197

B

1/2

13

C

1/2

13

0

5.1/2

140

E

10-1/2

267

F

12-3/4

324

-.

B

OM-1538

Page

2

SECTION

3INSTALLATION

4~

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

weld

control

and

welding

power

source.

and

disconnect

input

power

before

inspecting

or

installing.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

wetding

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.

3-1.

Typical

Equipment

Location

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

try

to

feed

wire

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body

when

threading

welding

wire.



HOT

SURFACES

can

burn

skin.



Allow

drive

assembly

and

gun

to

cool

before

touching.

Figure

3-1.

TypIcal

Equipment

LocatIon

3-2.

Installing

Pivot

Mounting

Bracket

Figure

3-2.

Installing

Pivot

Mounting

Bracket

Side

View

2

4

I

Welding

Power

Source

2

Side

Beam

3

Shunt

Control

4

Weld

Control

5

Wire

Drive

Assembly

1

Ref.

51-131

138

2

4

4

2

Robotic

model

not

equipped

with

pivot

bracket;

proceed

to

Section

3-3.

I

Motor

Mounting

Bracket

2

Mounting

Holes

3

Pivot

Bracket

Mount

motor

bracket

onto

pivot

bracket

using

hardware

from

pivot

bracket

as

shown.

To

adjust

position

of

pivot

bracket,

proceed

as

follows:

4

Securing

Screw

5

Clamp

Loosen

screws

on

clamp.

Adjust

pivot

bracket

position

as

neces

sary.

Tighten

securing

screws.

ST.158

543

Tools

Needed:

~

OM-1538

Pagie

3

3-3.

Removing

Vent

Screw

And

Mounting

Wire

Drive

Assembly

A~

CAUTION

LOSS

OF

GEAR

OIL

OR

DIRT

ENTERING

GEAR

CASE

DAMAGES

MOTOR.



Do

not

remove

either

vent

screw

if

both

are

at

the

bottom

or

positioned

so

that

gear

oil

runs

out.



Do

not

remove

either

vent

screw

if

dirt

can

easily

enter

gear

case.

3

1

Motor

Mounting

Bracket

2

Wire

Drive

Gears

3

Upper

Vent

Screw

Remove

and

discard

upper

vent

screw

before

operation.

4

Motor

Mount

motor

level

with

wire

drive

gear

end

so

that

gear

oil

does

not

enter

motor

seal.

Tools

Needed:

ST.156

578

Figure

3-3.

Removing

Vent

Screw

And

Mounting

Assembly

3-4.

Installing

Wire

Guide

And

Drive

Rolls



READ

Sectio

SAFETY

n

3

befor

BLOCKS

at

start

of

e

proceeding.

When

changing

wire

size

or

type,

check

drive

roll

and

guide

size

(see

Table

6-1

and

Table

6-2).

1

Wire

Guide

Securing

Screw

2

Inlet

Wire

GuideS

3

Intermediate

Wire

Guide

(Four-Drive

Roll

Models

Only)

Loosen

wire

guide

screws.

Slide

tip

as

close

to

drive

rolls

as

possible

without

touching.

Tighten

screw.

4

Drive

Gear

5

Pressure

Gear

Drive

and

pressure

gears

(1

of

each

in

two

drive

roll

model)

installed

be

fore

unit

is

shipped

from

factory.

6

Pressure

Gear

Assembly

Open

pressure

gear

assembly.

7

Drive

Roll

Tools

Needed:

1J~====1

7/16

in

L~D

9

5

4

8

Gear

Securing

Bolt

9

Drive

Roll

Securing

Screw

Install

correct

drive

roll

for

wire

size

and

type

using

supplied

hardware.

Close

pressure

gear

assembly.

ST-070

887.C

Do

not

tilt

assembly.

Position

assembly

level.

Figure

3-4.

Installing

Wire

Guide

And

Drive

Roll

(Four-Drive

Roll

Model

Shown)

OM-1538

Page

4

3-5.

Plug

Connections

Figure

3-5.

Plug

Connections

1

Plug

2

Keyway

3

Typical

Weld

Control

Connect

plug

to

matching

plug

from

weld

control.

To

connect

plugs,

align

keyways,

insert

plug,

and

tighten

connection.

ST.t58

933/

S.0149-A

3

Non-DIgital

Model

OM-1

538

Page

5

3-6.

Gun,

Weld

Cable

And

Gas

Connections

~

READ

SAFETY

BLOCKS

at

start

of

Section

3

before

proceeding.

Four-Drive

Roll

Model

I

Gun/Feeder

Securing

Knob

2

Gun/Feeder

Opening

Select

and

prepare

weld

cable

ac

cording

to

welding

power

source

manual.

6

Gun

Weld

Cable

Terminal

(Four-Drive

Roll

Models

Only)

For

guns

with

external

weld

cable.

connect

weld

cable

from

gun

toter

minal.

Gas

fitting

is

located

behind

gun/

feeder

opening.

For

guns

requiring

external

gas

connection,

remove

hose

from

fit

ting

and

connect

to

gun.

ST-156

544

Figure

3-6.

Gun,

Weld

Cable

And

Gas

Connections

3

Gun

End

Connect

To

Positive

(.4.)

Weld

Output

Terminal

On

Welding

Power

Source

For

Reverse

Polarity

Weld

Process

Or

Connect

To

Negative

()

Weld

Output

Terminal

On

Welding

Power

Source

For

Straight

Polarity

Weld

Process.

Loosen

knob.

Insert

gun

end

into

opening.

Position

as

close

as

pos

sible

to

drive

rolls

without

touching.

lighten

knob.

4

Weld

Cable

Terminal

5

Weld

Cable

7

Shielding

Gas

Fitting

8

Gas

Hose

2

3

6

Tools

Needed:

~

9/l6in

OM-1538

Page

6

3-7.

Threading

And

Feeding

Welding

Wire

Figure

3-7.

Thread

ing

An

d

Feeding

Welding

Wire

SECTION

4



OPERATION



ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Always

wear

dry

insulating

gloves.



Insulate

yourself

from

work

and

ground.

~

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



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

(MSDS5)

and

manufacturers

instructions

for

material

used.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.



.

h

RENTS

can

affect

pacemaker

operation.

MAGNETIC

FIELDS

FROM

HIGH

CUR



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

be.

sic

welding

safety

information.

wfw~m3.I~t9L



Allow

work

and

equipment

to

cool

before

handling,

.

Wear

dry

insulating

gloves,

safety

glasses

with

side

shields,

and

a

welding

helmet

with

a

correct

shade

of

filter

(see

ANSI

Z49.1).

5b3.1

AA

WARNING

READ

SAFETY

BLOCKS

at

start

of

Section

3

before

proceeding.

7

2

3

4

5

6

6

1

Wire

Spool

Loosen

wire

from

wire

spool,

cut

off

bent

wire,

and

pull

Bin

(150mm)

of

wire

off

spool.

2

Wire

Inlet

Guide

3

Drive

Roll

4

Intermediate

Wire

Guide

(Four-Drive

Roll

Models

Only)

5

Gun

Thread

wire

through

inlet

guide,

along

drive

rolls,

through

interme

diate

guide

and

drive

rolls

(if

appli

cable),

and

into

gun.

Se

sure

wire

is

in

correct

groove.

6

Pressure

Adjustment

Knob

And

Arm

Close

pressure

roll

assembly.

7

Adjusting

Pressure

Check

drive

roll

pressure

by

feed

ing

wire

against

a

wood

board

or

concrete

surface;

wire

should

feed

steadily

without

slipping.

If

pressure

adjustment

is

neces

sary,

tighten

pressure

knob(s).

ST-150

798

Tools

Needed:

Figure

4-1.

Safety

Equipment

OM-1538

Page

7

Figure

4-2.

Sequence

Of

Operation

SECTION

5-

MAINTENANCE

AND

TROUBLESHOOTING

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

weld

control

and

welding

power

source.

and

disconnect

Input

power

before

inspecting,

maintaining,

or

servicing.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

Figure

5-1.

Maintenance

I

Equipment

______________

Equipment

}

~1)I~Sourc~~

Install

&

))

Thread

&

Feed~\\

Put

On

Set

))

Turn

On

Turn

On

Control

Weld

Control

Shielding

Gas

And

Welding

Personal

Safety

I

Connect

Welding

Wire

)

Begin

We~~

HOT

PARTS

can

cause

severe

burns.



Allow

cooling

period

before

servicing

unit.

5-1.

Routine

Maintenance

Maintenance

to

be

performed

only

by

qualified

persons.

wtwam4.1

8/92

a

Turn

Off

all

power

before

main.

taming.

OM-1538

PageS

5-2.

Aligning

Drive

Rolls

And

Wire

Guides

Horizontal

Alignment

View

is

from

top

of

drive

rolls

look

ing

down

with

pressure

assembly

open.

1

Drive

Roil

Securing

Bolt

2

Drive

Roll

3

Wire

Guide

4

WeldIng

Wire

5

Drive

Gear

Turn

bolt

in

or

out

until

drive

roll

groove

lines

up

with

wire

guide.

Vertical

Alignment

6

HousIng

Bolts

7

Weld

Cable

Terminal

Loosen

bolts

and

terminal

nut(s).

8

Wire

Guide

9

Drive

Roll

10

Pressure

Roll

Slide

housing

up

or

down

until

groove

in

drive

roll

and

pressure

roll

line

up

with

wire

guide.

Tighten

hardware.

Close

pressure

roll

assembly.

Figure

5-2.

Aligning

Drive

Rolls

And

Wire

Guides

Horizontal

Alignment

Correct

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

2.

I

Incorrect

Vertical

Alignment

Two-Drive

Roil

Model

Four-Drive

Roll

Model

7

6

7

7

Tools

Needed:

7/16

in

~

9/l6in

S-0086

I

Ref.

57-080

487-C

/

Ret.

ST-070

885-B

/

S.0087

OM-1538

Page

9

5-3.

Brush

Inspection

And

Replacement

9

1/4

in(6.3

mm)~

Minimum

Length

I

Motor

2

Brush

Cap

Remove

cap.

3

Removing

Brush

4

Brush

Box

5

Spring

Assembly

Bracket

Remove

bracket

from

box.

6

Spring

Assembly

7

Brush

Pigtail

Pull

pigtail

to

remove

brush.

8

Brush

9

Checking

Brush

Replace

if

near

minimum

length.

10

Installing

Brush

To

reinstall

spring

assembly,

slide

into

box

as

shown

to

hook

bracket

into

box.

Install

brush

cap.

Check

brush

on

other

side

of

motor.

Figure

5-3.

Brush

Inspection

And

Replacement

7

Push

Back

And

Up

8

Pull

.3

Remove

Check

Side

View

Of

Box

Install

Tools

Needed:

Push

Up

And

Down

10

ST.156

693

OM-1538

Page

10

5-4.

Troubleshooting

I

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

weld

control

and

welding

power

source,

and

disconnect

input

power

before

inspecting.

maintaining,

or

servicing.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

HOT

PARTS

can

cause

severe

burns.



Allow

cooling

period

before

servicing

unit.

Table

5-1.

Troubleshooting

Align

drive

rolls.

*See

gun

or

weld

control

Owners

Manual.

d

Trouble

Troubleshooting

to

be

performed

only

by

qualified

persons.

wtwam4.1

8192

Wire

feeds

i~rratically.

Remedy

Check

gun

contact

tube

and

liner

sizes,

and

replace

if

necessary.

Check

for

obstruction

in

gun

contact

tube

or

liner.

Adjust

drive

roll

pressure

by

turning

pressure

adlustment

knob(s)

114

turn

clockwise

until

wire

stops

slipping.

Check

gun

contact

tube

for

obstructions.

Check

size

of

drive

roll.

Replace

drive

roll

if

worn.

--~

--~

---~

--~

--~

--~

--~

Clean

drive

roll,

and

check weld

control

hub

tension.

Motor

runs

~Iowly.

Section

*

*

3-4

3-4

5-2

Reduce

load.

Check

for

correct

input

voltage.

--~

--

--~

--

Motor

runs

at

full

speed

regardless

of

J.



..~

IHave

Factory

Authorized

Service

Station

check

Tachometer

board

J





wire

speed

setting

on

weld

control.

and

encoder

disc.

I

___________

OM-1538

Page

11

SECTION

6-

PARTS

LISt

Figure

6-1.

Motor

&

Drive

Assembly

(A1-2

Model

Illustrated)

SC-080

366-J

12

3

4

67

5

Includes

I

Items

10-15

46

34

r

36

30

38

47

S.

42

.5.

43

.5.

.5.

29

12

11

45

30

j

41

OM-1538

Page

12

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Miller A1-2 Owner's manual

Brand: Miller

Model: A1-2

Category: Welding System

Type: Owner's manual

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