Miller AMD-115G, Owner'S Manual

Page 1: ...AMD 115G AMD 115GR And AMD 115GH Processes Description Wire Feeder Automatic Welding OM 179082H 2017 02 File Advanced Manufacturing Systems For product information Owner s Manual translations and more visit www MillerWelds com ams ...

Page 2: ...ontinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operati...

Page 3: ...ments 8 2 5 Principales normes de sécurité 8 2 6 Informations relatives aux CEM 8 SECTION 3 DEFINITIONS 9 3 1 Additional Safety Symbols And Definitions 9 3 2 Miscellaneous Symbols And Definitions 9 SECTION 4 INSTALLATION 10 4 1 Specifications 10 4 2 Environmental Specifications 10 4 3 Overall Dimensions And Mounting Hole Layout 11 4 4 Typical Equipment Location 12 4 5 Installing Wire Guides And Dr...

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Page 5: ...kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not wor...

Page 6: ...pared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw frozen pipes D...

Page 7: ...TS can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels an...

Page 8: ...FPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there...

Page 9: ...ement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol Dans ces conditions utiliser les équipements suivants dans l ordre indiqué 1 un poste à souder DC à tension constante à fil 2 un...

Page 10: ... des brûlures Le contact accidentel de l électrode avec des objets métalliques peut provoquer des étincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage vérifier et s assurer que l endroit ne présente pas de danger D Déplacer toutes les substances inflammables à une distance de 10 7 m de l arc de soudage En cas d impossibilité les recouvrir soigneusementavec des p...

Page 11: ... appareil D Tenir l équipement câbles et cordons à distance des véhicules mobiles lors de toute opération en hauteur D Suivre les consignes du Manuel des applications pour l équation de levage NIOSH révisée Publication Nº94 110 lors du levage manuelle de pièces ou équipements lourds L EMPLOI EXCESSIF peut SURCHAUFFER L ÉQUIPEMENT D Prévoir une période de refroidissement res pecter le cycle opérato...

Page 12: ...al ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allie...

Page 13: ...y disposing at a designated collection facility Contact your local recycling office or your local distributor for further information Safe37 2012 05 Drive rolls can injure fingers Safe32 2012 05 Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away Safe33 2012 05 3 2 Miscellaneous Symbols And Definitions Some symbols are found only on CE products Ga...

Page 14: ... 115 VDC 0 75 A 2 ft 0 6 m 16 1 2 lb 7 5 kg AMD 4GH And AMD 115GH 90 To 1400 ipm 2 3 To 35 6 mpm 023 To 052 in 0 6 To 1 3 1 4 mm 4 2 Environmental Specifications A IP Rating IP Rating IP2X This equipment is designed for indoor use and is not intended to be used or stored outside IP2X 2014 06 B Temperature Specifications Operating Temperature Range Storage Transportation Temperature Range 14 to 104...

Page 15: ... 3 4 248 B 11 1 2 292 C 7 1 64 178 Inches Millimeters A 3 1 4 83 B 3 1 2 89 C 3 8 Dia 9 5 Dia 4 Holes 4 Holes C A B Adapter Bracket H C B Inches Millimeters A 7 178 B 3 1 2 89 C 3 1 4 83 D 6 152 E 5 1 2 140 F 1 1 2 38 G 25 64 Dia 9 9 Dia 2 Holes 2 Holes H 3 8 Dia 9 5 Dia 4 Holes 4 Holes A D G E F C A B ...

Page 16: ...ut 3 Drive Roll Carrier Turn nuts one click to line up lobes with lobes on drive roll carriers Open spring shaft carrier 4 Drive Roll Remove drive rolls 5 Wire Guide Securing Screw Loosen wire guide screws 6 Anti Wear Guide 7 Inlet Wire Guide Install inlet wire guide into anti wear guide and secure with setscrew Install inlet guide so groove is cen tered with screw and secure guide screw 8 Interme...

Page 17: ...res hose fitting with 5 8 18 right hand threads For guns requiring external gas connections remove hose from barbed fitting near gun feeder opening and connect to gun 4 Gun Feeder Securing Knob 5 Gun Feeder Opening 6 Gun End Loosen knob Insert gun end into opening Position as close as pos sible to drive rolls without touching Tighten knob 7 Weld Cable Terminal 8 Weld Cable Select and prepare weld ...

Page 18: ...ools Needed WOOD POWER ON OFF 6 in 150 mm Hold wire tightly to keep it from unraveling WIRE ADVANCE V Weld Control Welding Power Source Set switches Pull and hold wire cut off end Push wire thru guide up to drive rolls continue to hold welding wire Press Wire Advance push button until drive rolls grab wire Adjust tension until wire does not slip Press Wire Advance push button until wire comes out ...

Page 19: ...Gun Cables nl Cracked Parts Every 6 Months OR Drive Rolls Inside Unit 5 2 Brush Inspection And Replacement 137 390 C S 0816 1 Motor 2 Brush Cap Remove brush cap 3 Brush Replace brush if it becomes chipped or broken or if less than 1 4 in 6 4 mm of brush material is left Do not include spring boss as part of the 1 4 in measurement Install brush so that curved surface on end of brush matches curve o...

Page 20: ...orn wire guides Replace contact tip or liner See gun Owner s Manual Remove weld spatter or foreign matter from around gun nozzle opening Check and secure motor plug connection Have Factory Authorized Service Agent check drive motor Motor runs slowly Reduce load Check for correct input voltage Motor runs at full speed regardless of wire speed setting Have Factory Authorized Service Agent check digi...

Page 21: ...OM 179082 Page 17 Notes ...

Page 22: ...OM 179082 Page 18 SECTION 6 ELECTRICAL DIAGRAMS Figure 6 1 Circuit Diagram For AMD 4G AMD 4GR And AMD 4GH 180 590 ...

Page 23: ...OM 179082 Page 19 Figure 6 2 AMD 115G AMD 115GR And AMD 115GH 207 239 ...

Page 24: ...75 Carrier Drive Roll W Comp 1 3 149962 Spacer Carrier Drive Roll 4 4 149486 Pin Rotation Arm Rocker 2 5 163281 Spring Pressure Arm Retaining LH 2 5 165798 Spring Pressure Arm Retaining RH 2 6 150520 Spacer Flat Stl 257 ID x 619 OD x 105 2 7 132750 Arm Pressure 2 8 133493 Ring Retaining Ext 250 Shaft x 025thk 1 9 133350 Pin Hinge 1 10 M1 2 199571 Motor Gear 1 8hp 115VDC AMD 4GH Models including 1 ...

Page 25: ...d Digital Tach Amd 115 Only 1 28 132611 Optical Encoder Disc 1 29 167387 Spacer Locating 2 30 168825 Drive Pinion 24 Pitch 1 31 133308 Ring Retaining Ext 375 Shaft X 025thk 1 32 108940 Screw Cap Stl Hexhd 250 20 X 750 4 33 244579 Adapter Gun Feeder LH Includes 1 33 244587 Adapter Gun Feeder RH Includes 1 34 149959 Fitting Brs Barbed M 3 16tbg X 312 24 1 35 242259 Clamp Power Pin 1 36 242261 Lock P...

Page 26: ...49518 151024 087130 030 in 0 8 mm 150993 149518 151025 053695 035 in 0 9 mm 150993 149518 151026 053700 151036 072000 151052 132958 040 in 1 0 mm 150993 149518 161189 053696 045 in 1 1 1 2 mm 150994 149519 151027 053697 151037 053701 151053 132957 151070 083489 052 in 1 3 1 4 mm 150994 149519 151028 053698 151038 053702 151054 132956 151071 083490 1 16 in 062 in 1 6 mm 150995 149520 151029 053699 ...

Page 27: ...G Guns Subarc SAW Torches and External Cladding Heads Remote Controls and RFCS RJ45 Replacement Parts No labor Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on ...

Page 28: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...