Miller JB000000 Owner's manual

Brand: Miller

Model: JB000000

Type: Owner's manual

OWNER’S MANUAL

 1997 MILLER Electric Mfg. Co.

September 1997 FORM: OM-1093D

FRS-30E And FH-30B

1. Specifications

Flux recovery system and flux hopper

For automatic Submerged Arc (SAW) guns with flux flow control

Recovery system includes recovery box, hose, gun standoff bracket, gun body insulator, and pickup nozzles

Recovery system runs on compressed air

Flux hopper capacity: 30 lb (14 kg)

Air requirements: Pressure– 80 to 120 lb per square inch (552 to 827 kilopascals)

Volume– 20 cubic feet per minute (34 cubic meters per hour)

Recovery distance and speed: Height– up to 80 in (2032 mm) above welding surface

Speed– up to 30 oin (0.76 m) per minute

Flux hopper:: Height– 15 in (381 mm), Width– 12-1/2 in (318 mm), Length– 10-1/2 in (267 mm)

Weight– 13 lb (6 kg)

Flux recovery system: Height– 13-1/2 in (343 mm), Width– 15 in (381 mm), Length– 18 in (457 mm)

Weight– 26 lb (12 kg)

2. Safety Symbol Definitions

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Have only trained and qualified persons install, operate,

or service this unit. Call your distributor if you do not un-

derstand the directions. For WELDING SAFETY and

EMF information, read wire feeder and welding power

source manuals.

Beware of electric shock from wiring. Beware of moving parts.

Beware of electric shock from the cutting torch or wiring.

Touching the cutting torch while in contact with the work

or ground can cause electric shock. Always wear dry

gloves. Keep all panels and covers closed.

Hot flux and parts can cause burns. Welding makes flux

and parts very hot – let them cool before touching.

Cutting sparks can cause fire or explosion. Move flam-

mables away. Do not cut on closed tanks or barrels –

they can explode. Clean tanks or barrels properly.

Arc rays can burn eyes and skin – wear face protection

(helmet or face shield) with correct shade of filter, and

cover exposed skin with nonflammable clothing.

Allow cooling period. Reduce current or reduce duty cycle

before starting to cut again. Follow rated duty cycle.

Grinding causes flying pieces of metal and sparks. Wear

a face shield.

Wear safety glasses with side shields. Recycle or dispose of used flux in an environmentally

safe way.

OM-1093 Page 2

3. Flux Hopper Installation And Loading

ST-801 966

1 Flux Hopper

2 Mounting Bracket

The flux hopper should be mounted

on the fixture above the submerged

arc gun. The flux hopper must be

above the gun to ensure a gravity

flow of flux. A four foot (1.2 m) hose

is supplied to connect the flux hop-

per to the gun. Cut hose off to de-

sired length, and discard unused

portion.

3 Top Cover

4 Latches

To open the top cover, release

latches and lift off cover. A lift-out

screen is supplied to screen slag

and large particles from used flux.

Ensure that the flux inlet control on

the gun is closed while loading. If a

flux recovery system is installed on

the hopper, open cover of recovery

box to load or add flux.

OM-1093 Page 3

4. Flux Recovery System Installation

ST-801 967 / ST-801 968

1 Flux Recovery System

This system installs directly on the

top of the FH-30B flux hopper and is

secured in place by hopper cover

latches. To install the unit, proceed

as follows:

Remove cover from hopper.

Place recovery system on hopper

as shown in figure (flux screen must

remain in hopper).

Secure system to hopper by fully

closing latches.

Install pickup hose on air valve.

Install standoff bracket on insulated

portion of gun body. If gun body is

not insulated, install provided insu-

lator onto gun body before installing

standoff bracket.

Y Do not install standoff brack-

et on uninsulated gun body.

Do not install metal nozzle

on standoff bracket.

Y Always install provided insu-

lator around uninsulated

gun body, and connect hose

to standoff bracket.

Install desired nozzle in hose, and

secure hose to standoff bracket

with nozzle at desired position.

. It may be necessary to shape

(grind or cut) the nozzle to more

closely match the specific weld

bead or joint. The closer the

nozzle is to the welding sur-

face, the better the flux recov-

ery will be.

Y Hot flying particles can in-

jure personnel, start fires,

and damage equipment.

Shape nozzle only on grind-

er with proper guards in a

safe location wearing proper

face, hand, and body protec-

tion.

Install filter bag on exhaust pipe.

Connect air supply to air valve (see

figure). The valve will accept a stan-

dard air hose connector.

. Although moisture in air lines is

normally evaporated by hot flux

during recycling, it is recom-

mended that an in-line filter be

added and bled daily to avoid

possible moisture problems.

. Consult the flux manufacturer

for the proper ratio of new to re-

cycled flux.

Open cover to

add flux; close

during operation

Connect air

supply to valve

Install nozzle

in hose

Secure nozzle/hose at

desired position by

installing on supplied

gun standoff bracket

Air Supply

on/off lever

Remove cover from

hopper and install recovery

system on hopper

Install bag on

exhaust pipe

Install hose

on valve

. See Parts List for parts identification.

OM-1093 Page 4

5. Routine Maintenance

Y Disconnect power before maintaining.

Daily

Weekly

Check Flux Hoses For

Damage Or Leaks

Remove Bag, Shake Well, And If Needed,

Wash In Soap And Water. Dry Bag

Thoroughly And Reinstall.

Clean Flux Screen

Periodically (Depending On Usage)

Check Air Lines And Recovery Hose For Damage Or

Leaks. Repair Or Replace As Necessary.

3 Months

Replace Unreadable Labels

OM-1093 Page 5

6. Parts List

ST-801 970

. Hardware is common and

not available unless listed.

Figure 6-1. Flux Hopper

Description Quantity

Part

No.

Item

No.

1 049 441 SCREEN, strainer (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 019 677 HANDLE, door pull 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 049 442 BRACKET, mtg screen strainer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 082 811 COVER, flux hopper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

603 115 WEATHERSTRIPPING, adh .125 x .375 (order by ft) 4 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 045 981 STRIP, vinyl trans rgd .040 x 4.500 x 6.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 047 194 LATCH, door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 +082 813 CASE, flux hopper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 082 083 TUBING, PVC .875 ID x 1.125 OD (order by ft) 4ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 096 858 LABEL, warning exposed rays can burn eyes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 188 077 STRIP, vinyl trans rgd .040 x 3.000 x 13.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-1093 Page 6

Figure 6-2. Flux Recovery System

Description Quantity

Part

No.

Item

No.

1 083 009 FLUX BOX, recovery (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 047 194 LATCH, door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 084 854 WEATHERSTRIPPING, adh .250 x .750 (order by ft) 4 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

603 115 WEATHERSTRIPPING, adh .125 x .375 (order by ft) 4 ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 083 155 DEFLECTOR, air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 083 014 VENT, flux recovery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 010 863 CLAMP, hose 2.062-3.000clp dia slfttng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 083 612 FILTER, bag type cloth 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 082 908 O-RING, 2.250 ID x .210CS nprn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 083 349 COVER, flux box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 605 959 NUT, conduit No. 16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 083 297 INSULATOR, tube head 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 085 127 SCREW, thumb stl 10-32 x .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 083 008 NOZZLE, flux pick up 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 083 763 NOZZLE, flux pick up 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 010 497 CLAMP, hose .660-1.750clp dia 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 083 613 HOSE, duct 1.250 ID x 7ft lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 083 295 BRACKET, mtg nozzle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 083 286 BAR, support nozzle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 188 079 VALVE, air injection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 188 080 VALVE, shut off 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-891 969

. Hardware is common and

not available unless listed.