Miller GA-30A User manual

Miller

April

1995

Form:

OM-1521G

OWNERS

MANUAL

Guns

For

Automated

Applications



Read

and

these

instructions

safety

blocks

carefully.

Have

only

trained

and

qualified

install,

operate,

service

this

unit.

and

all

persons

Give

this

manual

the

operator.



For

help,

call

your

distributor

Call

your

distributor

you

not

understand

I~I

or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

the

directions.

Appleton,

54912

414-734-9821



GA-30A:

Air-Cooled

GMAW

Gun,

300

Amperes

100%

Duty

Cycle



GA-30A1:

Air-Cooled

GMAW

Gun,

300

Amperes

100%

Duty

Cycle



GA-40A:

Air-Cooled

GMAW

Gun,

400

Amperes

100%

Duty

Cycle



GA-50A:

Air-Cooled

GMAW

Gun,

500

Amperes

100%

Duty

Cycle



GA-5OCA:

Air-Cooled

GMAW

Gun,

500

Amperes

100%

Duty

Cycle



GW-60A:

Water-Cooled

GMAW

Gun,

600

Amps

100%

Duty

Cycle



GA-8OAC1:

Air-Cooled

SAW

Gun,

800

Amperes

100%

Duty

Cycle

cover

1/94

1995

MILLER

Electric

Mig.

Co.

PRINTED

USA

F

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1995

(Equipment

with

serial

number

preface

KD

newer)

This

limited

warranty

supersedes

all

MILLER

werranties

end

exclusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY



Subject

the

terms

end

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appteton,

Wisconsin,

warrants

its

original

retail

purchaser

that

new

MILLER

equipmenl

sold

after

the

effective

date

this

limited

warmnty

tree

tects

material

aid

workmanship

the

time

shipped

MtLLER.

THIS

WAR

RANTY

EXPRESSLY

LIEU

ALL

OTHER

WARRANTIES,

EXPRESS

tMPLtED,

INCLuDiNG

THE

WARRANTIES

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warrantj

periods

listed

below,

MILLER

will

repair

replace

any

war

mnted

parts

orcomponents

that

tail

due

such

defects

material

workmanship.

MILLER

must

notified

writing

within

thirty

(30)

days

auch

detect

failure,

which

time

MILLEF:

will

provide

instructions

the

warranty

claim

procedures

followed.

MILLER

shall

honor

warranty

claims

warranted

equipment

listed

below

the

event

such

failure

within

the

warranty

time

periods.

All

warranty

lime

periods

start

the

date

that

the

equipment

was

delivered

the

original

retail

purchaser,

one

year

after

the

equipment

sent

North

American

distributor

eighteen

months

after

the

equipment

sent

lnternstional

distributor.

Years

Partr.

3

Years

Labor

Original

main

power

rectifiers

Years



Parts

and

Labor



Transformer/Rectifier

Power

Sources

Plasma

Arc

Cuffing

Power

Sources

Semi-A

itomatic

and

Automatic

Wire

Feeders



Robots

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

the

engine

manufacturer.)



Air

Compressors

Year



Parts

and

Labor

Motor

Driven

Guns

Proces,

Controllers



Water

Coolant

Systems



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

the

product

they

are

installed

in,

for

minimum

one

year



whichever

ix greater.)

Months



Bafteries



Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

BIueTM

Limited

Warranty

shall

not

eppfy

to:

Items

furnished

MILLER,

but

manufactured

others,

such

engines

trade

accessories.

These

items

are

covered

the

manufacturers

warranty,

any.

Consumable

components;

such

contact

tips,

cufting

nozztes,

contscfors

and

relays

parts

that

tail

due

normal

wear.

Equipment

that

has

been

modified

any

party

other

than

MILLER,

equip

ment

that

has

been

improperfy installed.

improparfy

operated

misused

based

upon

industry

standards,

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

equipment

which

has

been

used

for

operation

outside

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

tNTENDED

FOR

PURCHASE

AND

USE

COMMER

CtAL/INDUSTFfIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

THE

USE

AND

MAINTENANCE

WELDING

EQUIPMENT

the

event

warranty

claim

covered

this

warranty,

the

exclusive

remedies

shall

be,

MILLERS

option:

(1)

repair;

(2)

replacement;

or,

where

authorized

writing

MILLER

appropriate

cases,

(3)

the

reasonable

cost

repair

replace

ment

authorized

MILLER

service

station;

(4)

payment

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

uae)

upon

return

Iha

goods

customers

risk

snd

expanse.

MILLERS

option

repair

replacement

will

FOB.,

Factory

Appleton,

Wisconsin,

FOB.

MILLER

authorized

ser

vice

facility

determined

MILLER.

Therefore

compensation

reimburse

ment

for

transportation

costs

any

kind

will

allowed.

THE

EXTENT

PERMITTED

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

EVENT

SHALL

MILLER

LIABLE

FOR

DIRECT

INDIRECT

SPECIAL,

INCIDENTAL

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS

PROFiT),

WHETHER

BASED

CON

TRACT

TORT

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

REPRESENTATION

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

TORT

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

CUSTOM

TRADE

COURSE

DEALING,

CLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

ALL

EOUtPMENT

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

Some

states

the

U.S.A.

nol

atlow

timifafions

how

long

implied

warranty

lasts,

the

exclusion

incidental,

indirect,

special

consequential

damages,

the

above

limitation

exclusion

may

not

apply

you.

This

warranty

provides

spe

cific

legaf

rights,

and

other

rights

may

avaifabla,

but

may

vary

from

state

to state.

Canada,

legislation

some

provinces

provides

for

certain

additional

warranties

remedies

other

than

stated

herein,

and

the extant

thaI

they

may

not

waived,

the

limitations

and

exclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

available,

but

may

J~,\vary

from

province

province.

I

Days



arts

and

Labor

M1G

Gins/TIG

Torches

APT

ZIPCUT

PLAZCUT

Model

Plasma

Cuffing

Torches



r......

RECEIVtNG-HANDLING

Before

Unpack

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

Shipment.

File

any

claims

for

loss

damage

with

the

deliv8ring

carrier,

Assistance

for

filing

settling

claims

may

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

Style

Number.

Use

the

following

spaces

record

Model

Designation

and

Serial

Style

Number

your

unit,

The

information

located

the

rating

label

nameplate.

Model

Serial

Style

No.

______________________________________________

Date

Purchase

miller

1/95

SAFETY

PRECAUTIONS

FOR

GMAW

GUNS

ELECTRIC

SHOCK

can

kill.

Always

wear

dry

insulating

gloves.

Insulate

yourself

from

work

and

ground.

not

touch

live

electrode

electrical

parts.

Repair

replace

worn,

damaged,

cracked

gun

cable

insulation.

Turn

off

welding

power

source

before

changing

contact

tip

gun

parts.

Keep

all

covers

and

handle

securely

place.

FUMES

AND

GASES

can

hazardous

your

health.

Keep

your

head

out

the

fumes.

Ventilate

area,

use

breathing

device.

Read

Material

Safety

Data

Sheets

(MSDSs)

and

manufacturers

instructions

for

material

used.

WELDING

can

cause

fire

explosion.

not

weld

near

flammable

material.

not

weld

closed

containers.

Watch

for

fire;

keep

extinguisher

nearby.

ARC

RAYS

can

burn

eyes

and

skin.

Wearwelding

helmetwith

correct

shade

filter.

Wear

correct

eye

and

body

protection.

Cover

exposed

skin

with

spatter-resistant

clothing.

SURFACES

can

burn

skin.

Allow

gun

cool

before

touching.

?i~!

not

touch

hot metal.

Protect

hot

metal

from

contact

others.

NOISE

can

damage

hearing;

SOME

APPLICATIONS,

SUCH

PULSING,

are

noisy.

Check

for

noise

level

limits

exceeding

those

specified

OSHA.

Use

approved

ear

plugs

ear

muffs

noise

level

high.

Warn

others

nearby

about

noise

hazard.

WELDING

WIRE

can

cause

puncture

wounds.

Keep

hands

and

body

away

from

gun

tip

when

trigger

pressed.

EMF

INFORMATION

WARNING

PROTECT

YOUI~SELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

GMAW

WELDING

can

hazardous.

welding,

most

jobs,

exposure

certain

hazards

occurs.

Welding

safe

when

precautions

are

taken.

The

safety

informatioii

given

below

only

summary

the

complete

safety

information

found

the

wire

feeder

and

welding

power

source

Owners

Manuals.

Read

and

all

safety

precautions.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

lED

PEoPLE.

NOTEL~

Considerations

About

Welding

And

The

Effects

Low

Frequency

Electric

And

Magnetic

Fields

The

following

quotation

from

the

General

Conclusions

Section

the

U.S.

Congress,

Office

Technology

Assessment,

Biological

Effects

Power

Frequency

Electric

Magnetic

Fields



Backg

round

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printir.g

Office,

May

1989):

.

. .

there

now

very

large

volume

of scientific

findings

based

experiments

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

this

work

very

high

quaIit~,

the

results

are

complex.

Current

scientific

understanding

doe~

not

yet

allow

interpret

the

evidence

single

coherent

framework.

Even

frustrating,

does

not

yet

allow

draw

definite

conclusions

about

questions

possible

risk

offer

clear

science-based

advice

strategies

minimize

avoid

potential

risks.

reduce

magnetic

fields

the

workplace,

use

the

following

procedures:

Keep

cables

together

twisting

taping

them.

Arrange

cables

one

side

and

away

from

the

operator.

not

coil

drape

cables

around

the

body.

Keep

welding

power

source

and

cables

far

away

practical.

Connect

work

clamp

workpiece

the

weld

possible.

About

Pacemakers:

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

information.

modlO

4/93

sr7

7/93

TABLE

CONTENTS

SECTION

SAFETY

INFORMATION

SECTION

2-.

SPECIFICATIONS

SECTION

3--

INSTALLATION

3-1.

Shielding

Gas

Nozzle

Adjustment

3-2.

Flux

Tube

Adjustment

SECTION

4--

OPERATION

SECTION

5--

MAINTENANCE

5-1.

Maintenance

And

Troubleshooting

5-2.

GA-30A

And

GA-30A1

Models

(GMAW)

5-3.

GA-40A

Models

(GMAW)

5-4.

GA-50A

Models

(GMAW)

5-5.

GiA-5OCA

Models

(GMAW)

5-6.

C-W-60A

Models

(GMAW)

5-7.

GA-8OAC1

Models

(SAW)

SECTION

PARTS

LIST

Figure

61.

Complete

Assembly

GA-30A

And

GA-30A1

Figure

62.

Complete

Assembly

GA-40A

Gun

Figure

63.

Complete

Assembly

GA-50A

Gun

Figure

6-4.

Complete

Assembly

GA-5OCA

Gun

Figure

6-5.

Complete

Assembly

GW-60A

Gun

Figure

6-6.

Complete

Assembly

GA-8OAC1

Gun

OM-15216



4/95

This manual suits for next models

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