Miller GA-30A User manual

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

TABLE
OF
CONTENTS
SECTION
1
-.
SAFETY INFORMATION
1
SECTION
2-.
SPECIFICATIONS
1
SECTION
3--
INSTALLATION
3-1.
Shielding
Gas Nozzle
Adjustment
3
3-2.
Flux Tube
Adjustment
4
SECTION
4--
OPERATION
4
SECTION
5--
MAINTENANCE
5-1.
Maintenance
And
Troubleshooting
5
5-2.
GA-30A
And
GA-30A1 Models
(GMAW)
6
5-3.
GA-40A Models
(GMAW)
7
5-4.
GA-50A
Models
(GMAW)
8
5-5.
GiA-5OCA
Models
(GMAW)
9
5-6.
C-W-60A
Models
(GMAW)
10
5-7.
GA-8OAC1 Models
(SAW)
12
SECTION
6
PARTS
LIST
Figure
61.
Complete Assembly
Of GA-30A And
GA-30A1
14
Figure
62.
Complete Assembly
Of GA-40A Gun
16
Figure
63.
Complete
Assembly
Of GA-50A Gun
18
Figure
6-4.
Complete Assembly
Of GA-5OCA Gun
20
Figure
6-5.
Complete Assembly
Of
GW-60A Gun
22
Figure
6-6.
Complete
Assembly
Of
GA-8OAC1
Gun
24
OM-15216

4/95

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.
3Statement
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