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Miller HF000000, MCA-1A Owner's manual

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June
1975
FORM:
OM-1504A
MODEL
MCA-1A
.030
WIRE
.035
WIRE
.045
WIRE
1/16
WIRE
STOCK
NO.
lOFT
15FT
078912
078917
078913
078918
078914 078919
078915
078 920
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
ADDITIONAL
COPY
PRICE
25
CENTS
t
SECTION
1
-
INTRODUCTION
Rating:
100
PCT.
Duty
Cycle,
dcrp
350
Amperes
With
CO2
Wire
Cable
and
Cooling
J_
Dia.
Hose
Length
Method
.030
(.7mm)
To
10
Air
.045
(1.1mm)
Hard
15
Air
Net
Weight
14
Lbs.
(6.3
Kilos)
16
Lbs.
(7.2
Kilos)
Ship
Weight
16
Lbs.
(7.2
Kilos)
18
Lbs.
(8.1
Kilos)
Figure
1-1.
Specifications
1-1.
GENERAL
1-2.
RECEIVING-HANDLING
This
gun
is
designed
specifically
for
use
in
conjunction
with
the
Gas
Metal-Arc
(MIG)
Welding
process.
The
gun
is
shipped
with
the
necessary
components
for
the
specific
wire
size
ordered.
Through
minor
changes
in
parts
the
gun
may
be
used
with
.030,
.035,
.045,
or
1/16
wire.
1-4.
SAFETY
I
U
I
I
CAUTION
II
IMPORTA~
r~E1
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2-
INSTALLATION
Prior
to
installing
the
gun,
ensure
that
the
control/
feeder
and
welding
power
source
are
both
completely
disconnected
from
the
respective
input
electrical
power
supplies.
2-3.
ELECTRODE
WIRE
OUTLET
CONNECTION
(Fig
ure
2-1)
Proceed
as
follows
to
install
the
Electrode
Wire
Gun
Connec
tor
into
the
drive
assembly
on
the
control/feeder:
1.
Rotate
the
Gun
Connector
Securing
Knob
or
Screw
in
a
counterclockwise
direction
four
complete
turns.
2-1.
SHIELDING
GAS
HOSE
CONNECTION
(Figure
2-1)
Secure
the
shielding
gas
hose
connector
in
the
shielding
gas
output
connector
on
the
control/feeder
or
to
whatever
device
that
is
to
be
used
for
on-off
control
of
the
shielding
gas.
The
shielding
gas
hose
connector
has
right
hand
threading.
2-2.
GUN
SWITCH
CONNECTION
(Figure
2-1)
Insert
the
amphenol
plug
from
the
Gun
Switch
fully
into
the
Switch
Control
Receptacle
on
the
control/feeder.
Once
fully
inserted
into
the
receptacle,
rotate
the
plug
collar
as
far
as
it
will
turn
in
a
clockwise
direction;
this
will
lock
the
plug
in
the
receptacle
and
prevent
the
plug
from
coming
Out
under
tension.
2.
Insert
the
Electrode
Wire
Gun
Connector
fully
into
the
outlet
guide
hole
with
the
flat
side
of
the
connector
fac
ing
the
roll
pin
inside
of
the
outlet
guide
hole.
3.
Rotate
the
Electrode
Wire
Gun
Connector
90
degrees
in
a
clockwise
direction.
4.
Rotate
the
Gun
Connector
Securing
Knob
or
Screw
as
far
as
it
will
turn
in
a
clockwise
direction.
2-4.
CHANGING
WIRE
SIZES
(Figure
2-1)
Each
time
the
size
of
the
electrode
wire
being
used
is
changed
it
will
be
necessary
to
change
certain
components
so
that
the
holes
in
these
components
will
permit
proper
movement
of
the electrode
wire.
The
following
steps
explain
the
proce
dures
necessary
to
adapt
the
gun
to
either
.030, .035,
.045,
or
1/16
wire.
This
manual
has
been
prepared
especially
for
use
in
familiar
izin~
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
informa
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
It
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
safety
hazard
to
personnel.
I
I
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip.
meht.
I
I
OM-1504
Page
1
NOTE
If
it
is
desired
to
convert
from
.030
to
.035
wire
or
from
.045
to
1/16
wire,
only
the
contact
tube
(item
3
Figure
2-1)
will
have
to
be
changed.
However,
if
the
gun
is
equipped
for
.030
or
.035
wire
and
it
is
desired
to
convert
to
.045
or
1/16
wire
(or
vice
versa),
all
of
the
following
steps
will
have
to
be
performed.
install
nut
(8)
onto
the
head
tube,
washer
(7)
on
nut
(8),
adapter
(6)
into
the
head
tube,
centering
insulator
(5)
Onto
adapter
(6),
contact
tube
(3)
into
adapter
(6),
and
nozzle
(4)
onto
nut
(8).
7.
Loosen
set
screw
(9).
8.
Pull
Out
monocoil
(11)
from
Electrode
Wire
Gun
Con
nector
(10).
IMPORTANT
1.
Cut
off
any
portion
of
the
electrode
wire
which
ex
tends
beyond
the
end
of
the
contact
tube
(3).
2.
Pull
out
all
of
the
electrode
wire
which
is
in
the
gun
monocoil
and
rewind
it
Onto
the
wire
spool.
recommended
that
the
monocoil
casing
(12)
and
monocoil
(11)
both
have
the
inside
blown
Out
with
compressed
air
prior
to
assembly.
3.
Remove
nozzle
(4).
4.
Remove
contact
tube
(3).
5.
If
converting
from
.030
or
.035
wire
to
.045
or
1/16
wire,
remove
insulator
(2)
and
adapter
(1).
If
convert
ing
from
.045
or
1/16
wire
to
.030
or
.035
wire,
remove
centering
insulator
(5),
adapter
(6),
washer
(7).and
nut
(8).
6.
To
adapt
the
gun
for
.030
or
.035
wire,
install
adapter
(1)
into
the
head
tube,
insulator
(2)
onto
adapter
(1),
contact
tube
(3)
into
adapter
(1),
and
nozzle
(4)
onto
insulator
(2).
To
adapt
the
gun
for
.045
or
1/16
wire,
9.
Lay
old
monocoil
(11)
along
side
of
new
monocoil
and
cut
new
monocoil
to
the
same
length
as
the
old
monocoil.
10.
Insert.
monocoil
(11)
into
the
Electrode
Wire
Gun
Connector
(10).
11.
Continue
to
feed
monocoil
(11)
intO
the
monocoil
casing
(12)
until
the
end
of
the
monocoil
is
flush
with
the
end
of
the
Electrode
Wire
Gun
Connector
(10).
12.
Tighten
set
screw
(9).
Figure
2-1.
Gun
Components
I
t
4
3
2
5
6
7
8
jielding
Gas
Hose
Connector
10
11
12
Electrode
Wire
Gun
Connector
Gun
Switch
Plug
TB-078
912-2
Page
2
June
1975
FORM:
OM-1504A
MODEL
MCA-1A
.030
WIRE
.035
WIRE
.045
WIRE
1/16
WIRE
STOCK
10
FT
078
912
078913
078 914
078
915
NO.
15
Ft
078917
078
918
078919
078
920
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
36
35
39
40
41
3,
-12
9
10
Figure
A
Exploded
View
of
Gun
Assembly
42
32
31
22
13
ii
18
19
20
43
Includes
Items
26
TC-078
912A
OM-1504
Page
1
THE
FOLLOWING
WIRE
GUIDE
KITS
ARE
AVAILABLE
TO
CHANGE
THE
GUN
FROM
ONE
WIRE
SiZE
TO
ANOTHER.
SEE
VIEW
ON
PAGE
1
FOR
IDENTIFICATION
OF
ITEM
NUMBERS.
Quantity
Model
10
Foot
15
Foot
.8MM
.9MM
1.2MM
1.6MM
.8MM
.9MM
1.2MM
1.6MM
.031
.035
.047
.063
.031
.035
.047
.063
.
.035
.045
1/16
.030
.035~
.045
1/16
N
C)
~
0)
0
N
N
N N
N
0
N
N
N
N
0
0
0
0
(0 (0
(0
(0
~
CO
N N
N
N
N
N
N
N
o o
0
0
0
0
0
0
1
1 1
1
1
1
1
1
5
5
BE
SURE TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Factory
No
Part
No.
Description
Kit,
Wire
Guide
3
076086
ADAPTER,tube-contact
4
075
892
INSULATOR,
nozzle
5
075
788
TUBE,
contact
.030
wire
5
075 789
TUBE,
contact
.035
wire
5
5
5
075
613
TUBE,
contact
.045
wire
5
5
5
075614
TUBE,contactl/l6wire
5
5
6
076
029
NOZZLE
1
1 1
1
6
075
953
NOZZLE
1
1
1
1
7
073
225
INSULATOR,
centering
-
head
tube
1
1
1
1
8
075
946
ADAPTER,
tube
-
contact
1
1
.
.
1
1
9
073
778
WASHER,
phenolic
-
flat
1
1 1
1
10
075
928
NUT,
nozzle
1
1 1
1
20
075814
LINER,monocoil
1
1
20
075963
LINER,monocoil
1
1
20
075815
LINER,monocoil
1
1
20
075964
LINER,monocoil
1
1
Page
3
/