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- Page 1 OM-256 907A 2012−04 Processes Submerged (SAW) Welding Description Heavy Duty Wire Feeder For Automated Welding Applications Enhanced Feed Wire Drive RAD-400EF, RAD-400EFT and RAD-780EF Motor/Drive Assemblies 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.
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Page 3: Table Des Matières
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1. - Page 4 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. - Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging feature designed for this purpose. -
Page 8: California Proposition 65 Warnings
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer. -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. - Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser. -
Page 12: Proposition Californienne 65 Avertissements
Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent... -
Page 13: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com). - Page 14 OM-256 907 Page 10...
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Page 15: Section 3 − Definitions
SECTION 3 − DEFINITIONS 3-1. Warning Label Electric Shock and Pinch Points Warning! Watch Out! There are possible hazards as shown by the symbols. Drive rolls can injure fingers Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away. -
Page 16: Section 4 − Installation
SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person. -
Page 17: Description
4-4. Description Motor/drive Assembly This unit is a heavy-duty wire feed- ing motor/drive assembly designed for automated Submerged Arc Welding (SAW) applications. The various model designations in- dicate information about the specif- ic model. The units are offered in ei- ther standard speed or high speed drives. -
Page 18: Typical Equipment Location
4-6. Typical Equipment Location Side View Front View 804 907-A Welding Power Source Weld Control Wire Drive Assembly Side Beam Spool Support Sub-Arc Welding Torch Flux Hopper Notes OM-256 907 Page 14... -
Page 19: Installing Wire Guide And Drive Roll
4-7. Installing Wire Guide And Drive Roll When changing wire size or type, check drive roll size (see Table 5-1). Wire Pressure Adjustment Screw Loosen screw to decrease tension on spring. Drive Roll Nut Drive Roll Remove drive roll. Drive Roll Carrier Turn nut one click to line up lobes with lobes on drive roll carrier. -
Page 20: Plug Connections
4-8. Plug Connections Weld Control Motor Control Cord (Not Supplied) Motor/Drive Assembly To make connections, align key- way, insert plug, and tighten threaded collar. Motor shown without feed roller guard. 257 106-A OM-256 907 Page 16... -
Page 21: Threading And Feeding Welding Wire
4-9. Threading And Feeding Welding Wire Hold wire tightly to keep it from unraveling. POWER Tools Needed: 6 in. Weld Control Welding Power Source (150 mm) Pull and hold wire; cut off end. Set switches. WIRE ADVANCE Motor shown without feed roller guard. -
Page 22: Manually Changing Feed Plate Angle
4-11. Manually Changing Feed Plate Angle Adjusting Knob Turn adjusting knob to change torch angle. Hub Clamp Screw Tighten screw. Feed Plate Screw Loosen screw. The feed plate maximum tilt angle is about 15 degrees from center in both directions. Motor shown Tools Needed: without... -
Page 23: Location Of Torch For Tandem Arc Applications
4-12. Location Of Torch For Tandem Arc Applications Follow instructions below to change torch to right of center or left of center. Assembly As Shipped (With torch right of center) Tools Needed: 1/4, 3/16 in. Motor shown without Torch Left Of Center Torch Right Of Center feed roller guard. -
Page 24: Section 5 − Maintenance And Troubleshooting
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Disconnect power before maintaining. 3 Months Clean Repair Or Replace Replace Unreadable Tighten Cracked Labels Weld Weld Terminals Cable Replace Cord Cracked Hose Cable Parts 6 Months Blow Out Or Clean Vacuum Inside. -
Page 25: Brush Inspection And Replacement
5-2. Brush Inspection And Replacement Brush Cap Spring Clip Brush 3/8 in. (9.5 mm) Minimum Length Remove brush cap. Remove spring clip and brush. 3/4 in. (19 mm) Replace brush if it becomes chipped New Length or broken, or if less than 3/8 in. (9.5 mm) of brush material is left. -
Page 26: Section 6 − Electrical Diagram
SECTION 6 − ELECTRICAL DIAGRAM PLG1 GREEN Motor BROWN PLG1 BARE GREEN BLACK TACH WHITE Figure 6-1. Circuit Diagram OM-256 907 Page 22... - Page 27 Notes OM-256 907 Page 23...
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Page 28: Section 7 − Parts List
SECTION 7 − PARTS LIST Hardware is common and not available unless listed. 44 45 9 10 33 31 Shown For Reference See Table 7-1 For Replacement Drive Rolls 254 617-A Figure 7-1. Wire Drive Assembly Item Dia. Part Mkgs. Description Quantity 301 102... - Page 29 Item Dia. Part Mkgs. Description Quantity 301 102 Figure 7-1. Wire Drive Assembly (Continued) 301 104 301 103 ... . 253 249 ..Bracket, Motor Hub .
- Page 30 Notes...
- Page 31 Effective January 1, 2012 (Equipment with a serial number preface of MC 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 90 Days —...
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Page 32: For Service
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. ORIGINAL INSTRUCTIONS − PRINTED IN USA 2012 Miller Electric Mfg. Co. 2012−01...