Miller AID115GB Owner's Manual
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Miller AID115GB Owner's Manual

Miller AID115GB Owner's Manual

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OM-221 785B
2006−05
Processes
Automatic Welding
Description
Wire Feeder
AID115GB w/OCP And
AID115GBR w/OCP
File: Advanced Manufacturing Systems
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller AID115GB

  • Page 1 OM-221 785B 2006−05 Processes Automatic Welding Description Wire Feeder AID115GB w/OCP And AID115GBR w/OCP File: Advanced Manufacturing Systems Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    D Read Owner’s Manual before using or servic- support unit. ing unit. D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement long enough to extend beyond opposite side of parts. unit.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Utiliser un équipement de levage de capacité D Utiliser uniquement des pièces de rechange suffisante pour lever l’appareil. Miller/Hobart. D En utilisant des fourches de levage pour déplacer l’unité, s’assu- rer que les fourches sont suffisamment longues pour dépasser du côté...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.org).

  • Page 13: Section 3 − Installation

    Range Power Ship 50 To 1400 ipm .023 To 1/8 in 16-1/2 lb 17-1/2 lb AID115GB 115 VDC, 75 A 2 ft (0.6 m) (1.3 To 35.6 mpm) (0.6 To 1.3/1.4 mm) (7.5 kg) (7.9 kg) 3-2. Overall Dimensions And Mounting Hole Layout...

  • Page 14: Typical Equipment Location

    3-3. Typical Equipment Location Welding Power Source Weld Control Wire Drive Assembly Gas Cylinder Spool Support Automatic Welding Gun Side Beam ST-131 138-A 3-4. Installing Wire Guides And Drive Rolls When changing wire size or type, check drive roll and guide size (see Table 6-1).

  • Page 15: Motor Mounting And Gun, Weld Cable, And Gas Connections

    3-5. Motor Mounting And Gun, Weld Cable, And Gas Connections Drive motor must be isolated from weld potential. Insulator Plate When mounting motor, place factory-supplied insulator plate under motor mounting bracket to provide isolation. Customer Supplied Gas Hose Shielding Gas Valve Fitting Requires hose fitting with 5/8-18 right-hand threads.

  • Page 16: Plug Connections

    3-6. Plug Connections Weld Control Motor Control Cord (Not Supplied) Cord is available in 20 ft (6.1 m), 30 ft (9.1 m) or 50 ft (15.2 m) lengths. Motor/Drive Assembly To make connections, align key- way, insert plug, and tighten threaded collar.

  • Page 17: Section 4 − Maintenance And Troubleshooting

    SECTION 4 − MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent E E very l Unreadable Labels ~ Weld Terminals...

  • Page 18: Troubleshooting

    4-3. Troubleshooting Trouble Remedy Electrode wire feeding stops or feeds er- Readjust hub tension and drive roll pressure. ratically during welding ratically during welding. Change to correct size drive roll. Clean or replace dirty or worn drive roll. Incorrect size or worn wire guides. Replace contact tip or liner.
  • Page 19 226 049-A Figure 5-2. Circuit Diagram For AID-115/Gas Box (Right Hand) OM-221 785 Page 15...

  • Page 20: Section 6 − Parts List

    SECTION 6 − PARTS LIST See Table 6-1 Drive Roll & Wire Guide Kits Hardware is common and not available unless listed. 804 389-A Figure 6-1. Drive Assembly, Wire Item Dia. Part Description Quantity Mkgs. Figure 6-1. Drive Assembly, Wire .
  • Page 21 Item Dia. Part Description Quantity Mkgs. Figure 6-1. Drive Assembly, Wire (Continued) ....203 631 PRESSURE ARM ASSY LH (including) ......
  • Page 22 Table 6-1. Drive Roll And Wire Guide Kits Wire Size V-GROOVE U-GROOVE VK-GROOVE UC-GROOVE Inter- Inter Inlet Inlet mediate 4 Roll Drive 4 Roll Drive 4 Roll Drive 4 Roll Drive Guide Fraction Metric Guide Roll Roll Roll Roll .023-.025 in. 0.6 mm 150 993 149 518...
  • Page 23 Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...
  • Page 24 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © PRINTED IN USA 2006 Miller Electric Mfg. Co. 2006−01...

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