Miller Electric Millermatic 180 Owner`s manual

OM-225 311C
2007−05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
R
Millermatic 140,
140 Auto−Set , And 180
And M-10 Gun
™
Visit our website at
www.MillerWelds.com
File: MIG (GMAW)
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue 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 operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2005−04
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Work Cable Routing Inside Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Changing Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Selecting A Location And Connecting Input Power For 115 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Selecting A Location And Connecting Input Power For 230 VAC Model . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Electrical Service Guide For 230 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Removing MIG Gun From Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Installing Optional Spool Gun Switch In Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Connecting Spool Gun To Millermatic 140/180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls For 115 VAC Model w/Auto-Sett . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Controls For 115 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Controls For 230 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Weld Parameter Chart For 115 VAC Model w/Auto−Sett . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Weld Parameter Chart For 115 VAC Model w/Factory Set
Non-Wire Speed Tracking Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Weld Parameter Chart For 115 VAC Model w/Wire Speed Tracking Mode . . . . . . . . . . . . . . . . . . . . . .
5-7. Weld Parameter Chart For 230 VAC Model w/Factory Set
Non-Wire Speed Tracking Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Weld Parameter Chart For 230 VAC Model w/Wire Speed Tracking Mode . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 6 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Drive Motor Protection And Tip Saver/Short Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Changing Drive Roll Or Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Cleaning Or Replacing Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Replacing Switch And/Or Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Gun Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Troubleshooting − Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Troubleshooting − Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Troubleshooting − Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Troubleshooting − Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Troubleshooting − Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-13. Troubleshooting − Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-14. Troubleshooting − Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-15. Troubleshooting − Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-16. Common MIG Shielding Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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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.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D
D
D
D
D
D
Y During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D
D
D
D
D
D
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
OM-225 311 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
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 Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-225 311 Page 2
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
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 as
necessary.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-225 311 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-225 311 Page 4
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 your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
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 procédure comporte des risques possibles ! Les dangers éventuels sont représentés par les symboles graphiques joints.
Y Indique un message de sécurité particulier
. Signifie NOTE ; n’est pas relatif à la sécurité.
2-2.
Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
les dangers.
Dangers relatifs au soudage à l’arc
Y Les symboles représentés ci-dessous sont utilisés dans ce manuel
pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions en
matière de sécurité indiquées ci-dessous ne constituent qu’un
sommaire des instructions de sécurité plus complètes fournies
dans les normes de sécurité énumérées dans la Section 2-5. Lire et
observer toutes les normes de sécurité.
Y Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Y Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
D
D
D
D
D
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
D
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
D
D
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et sans
D
D
D
D
D
D
D
D
D
trous.
S’isoler de la pièce à couper et du sol en utilisant des housses ou des
tapis assez grands afin d’éviter tout contact physique avec la pièce à
couper ou le sol.
Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si
le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est
équipé.
D’autres consignes de sécurité sont nécessaires dans les conditions
suivantes : risques électriques dans un environnement humide ou si l’on
porte des vêtements mouillés ; sur des structures métalliques telles 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 poste à souder DC manuel (électrode)
ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des
situations, l’utilisation d’un poste à souder DC à fil à tension constante
est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder
à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer le poste correctement et le mettre à la terre convenablement
selon les consignes du manuel de l’opérateur et les normes nationales,
provinciales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer
que le fil de terre du cordon d’alimentation est bien raccordé à la borne
de terre du sectionneur ou que la fiche du cordon est raccordée à une
prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D
D
D
n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu
peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante
ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre
ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines en
même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement en
place.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à
une même borne de sortie de soudage.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour la santé.
D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces vapeurs.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et
les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de
soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de
respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait
été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en
portant un respirateur à alimentation d’air. Les revêtements et tous les
métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.
OM-225 311 Page 5
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau.
Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection
d’étincelles, des pièces chaudes et des équipements chauds peuvent
provoquer des incendies et des brûlures. Le contact accidentel de
l’électrode avec des objets métalliques peut provoquer des étincelles,
une explosion, une surchauffe 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 soigneusement avec des protections homologuées.
D Ne pas souder dans un endroit où des étincelles peuvent tomber sur
des substances inflammables.
D Se protéger, ainsi que toute autre personne travaillant sur les lieux,
contre les étincelles et le métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
extincteur à la portée de main.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une longue
distance par des chemins inconnus éventuels en provoquant des
risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites
gelées.
D En cas de non-utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D Avant de souder, retirer toute substance combustible de ses poches
telles qu’un allumeur au butane ou des allumettes.
D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B
pour travaux de soudage et prévoir un détecteur d’incendie et un extincteur à proximité.
DES
PARTICULES
VOLANTES
peuvent blesser les yeux.
D Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage
génèrent des étincelles et des particules
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent
de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
OM-225 311 Page 6
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D Ne pas toucher des parties chaudes à mains
nues.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, rester
à distance.
D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc,
de gougeage ou de soudage par points.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de soudage,
les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3.
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de
produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LA CHUTE DE L’APPAREIL peut
blesser.
LIRE LES INSTRUCTIONS.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut
CHAUFFER L’ÉQUIPEMENT.
D Lire le manuel d’utilisation avant d’utiliser ou
d’intervenir sur l’appareil.
D Utiliser uniquement des pièces de rechange
Miller/Hobart.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
SUR-
D Prévoir une période de refroidissement ;
respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
D
D
D
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits
imprimés.
D
D
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes PC.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
D
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de soudage.
2-4.
D Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipements de radio-navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement
l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une
distance correcte et utiliser une terre et un blindage pour réduire
les interférences éventuelles.
D
D L’énergie électromagnétique peut gêner le
fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.
D Veiller à ce que tout l’équipement de la zone de
soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de
câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
Proposition californienne 65 Avertissements
Y Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques dont
l’État de Californie reconnaît qu’ils provoquent des malformations
congénitales et, dans certains cas, des cancers. (Code de santé et
de sécurité de Californie, chapitre 25249.5 et suivants)
Pour les moteurs à essence :
Y Les gaz d’échappement des moteurs contiennent des produits
chimiques dont l’État de Californie reconnaît qu’ils provoquent
des cancers et des malformations congénitales ou autres problèmes de procréation.
Y Les batteries, les bornes et autres accessoires contiennent du
plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.
Pour les moteurs diesel :
Y Les gaz d’échappement des moteurs diesel et certains de leurs
composants sont reconnus par l’État de Californie comme
provoquant des cancers et des malformations congénitales ou autres problèmes de procréation.
OM-225 311 Page 7
2-5.
Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
800-463-6727 ou à Toronto 416-747-4044, site Internet :
www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS
F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, Standards Sales, 178 Rexdale
2-6.
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).
Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un
certain souci à propos de tels champs. Cependant, après avoir examiné
plus de 500 études qui ont été faites pendant une période de recherche
de 17 ans, un comité spécial ruban bleu du National Research Council a
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ».
Toutefois, des études sont toujours en cours et les preuves continuent à
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-225 311 Page 8
1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la soudure.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
. A complete Parts List is available on-line at www.MillerWelds.com
SECTION 3 − SPECIFICATIONS
3-1. Specifications
A. 115 VAC Model
Rated Welding
Output
Maximum
Open-Circuit
Voltage DC
Amperage Range
KVA
KW
Weight
W/ Gun
Overall
Dimensions
Length: 17-1/2 in
(444 mm)
90 A @ 18
Volts DC, 20%
Duty Cycle
30 − 140
20
2.8
2.4
15*
2.1*
1.8*
28
63 A @ 21
Volts DC, 20%
Duty Cycle*
60 lb
(27 kg)
Width: 10-5/8 in
(273 mm)
Height: 15-3/4 in
(400 mm)
Solid
Wire Type
And Dia
Amperes Input at
Rated Load Output 115 V, 60 Hz,
Single-Phase
Stainless
.024 - .030 in
(0.6 - 0.8
mm)
.023 - .030 in
(0.6 - 0.8
mm)
Flux Cored
Wire Feed Speed Range w/Wire Feed Speed Tracking On
.030 - .035 in
(0.8 - 0.9 mm)
45 − 500 IPM (1.1 − 12.7 m/min) At No Load
40 − 500 IPM (1.0 − 12.7 m/min) Feeding Wire
* CSA Rating
B. 115 VAC Model w/Auto−SetE
Rated Welding
Output
Maximum
Open-Circuit
Voltage DC
Amperage Range
KVA
KW
Weight
W/ Gun
Overall
Dimensions
Length: 17-1/2 in
(444 mm)
90 A @ 18
Volts DC, 20%
Duty Cycle
30 − 140
20
2.8
2.4
15*
2.1*
1.8*
28
63 A @ 21
Volts DC, 20%
Duty Cycle*
60 lb
(27 kg)
Width: 10-5/8 in
(273 mm)
Height: 15-3/4 in
(400 mm)
Solid
Wire Type
And Dia
Amperes Input at
Rated Load Output 115 V, 60 Hz,
Single-Phase
Stainless
.024 - .030 in
(0.6 - 0.8
mm)
.023 - .030 in
(0.6 - 0.8
mm)
Flux Cored
Wire Feed Speed Range
.030 - .035 in
(0.8 - 0.9 mm)
35 − 420 IPM (0.9 − 10.7 m/min) At No Load
15 − 390 IPM (0.4 − 9.9 m/min) Feeding Wire
* CSA Rating
C. 230 VAC Model
Rated Welding
Output
Amperage
Range
Maximum OpenCircuit Voltage
DC
Amperes Input at
Rated Load Output
230 V, 60 Hz,
Single-Phase
KVA
KW
Weight
W/ Gun
Overall
Dimensions
Length: 17-1/2 in
(444 mm)
135 A @ 22.5 Volts
DC, 30% Duty Cycle
At 60 Hz Input
30 − 180
31
21.7
5.0
4.1
72 lb
(32.7 kg)
Width: 10-5/8 in
(273 mm)
Height: 15-3/4 in
(400 mm)
Wire Type
And Dia
Solid/
Stainless
Flux Cored
.024 − .035 in
(0.6 − 0.9 mm)
.030 − .045 in
(0.8 − 1.2 mm)
Wire Feed Speed Range w/Wire Feed Speed Tracking On
100 − 725 IPM (2.5 − 18.4 m/min) At No Load
90 − 700 IPM (2.3 − 17.8 m/min) Feeding Wire
OM-225 311 Page 9
. A complete Parts List is available on-line at www.MillerWelds.com
3-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
A. 115 VAC
Model
Y Exceeding duty cycle can
damage unit or gun and void
warranty.
20% duty cycle at 90 amps
2 Minutes Welding
8 Minutes Resting
B. 230 VAC
Model
30% duty cycle at 135 amps, 60 Hz
3 Minutes Welding
7 Minutes Resting
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 230 342-A / 230 343-A
OM-225 311 Page 10
. A complete Parts List is available on-line at www.MillerWelds.com
3-3. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
A. 115 VAC Model
30
25
VOLTAGE
20
MAX
MIN
15
10
5
0
0
20
40
60
80
100
AMPERAGE
120
140
160
B. 230 VAC Model
30
25
VOLTAGE
20
MAX
MIN
15
10
5
0
0
20
40
60
80 100 120
AMPERAGE
140
160
180
200
225 265-A / 228 250-A
OM-225 311 Page 11
. A complete Parts List is available on-line at www.MillerWelds.com
SECTION 4 − INSTALLATION
4-1. Installing Welding Gun
1
2
3
Drive Assembly
Gun Securing Knob
Gun End
Loosen knob. Insert gun end
through opening until it bottoms
against drive assembly. Tighten
knob.
4
3
Gun Trigger Plug
Insert into receptacle, and tighten
threaded collar.
4
Close door.
1
2
. Be sure that gun end is tight against drive assembly.
3
3
Correct
Incorrect
Ref. 802 982-A / Ref. 801 987
4-2. Installing Work Clamp
. Connection hardware must be tightened with proper tools. Do not just
hand tighten hardware. A loose electrical connection will cause poor
weld performance and excessive heating of the work clamp.
1
2
3
4
5
Nut
Work Cable From Unit
Work Clamp
Screw
Work Clamp Tabs
Bend tabs around work cable.
6
3
1
Insulating Sleeves
Slide one insulating sleeve over
work cable before connecting to
clamp.
Slide insulating
handles.
6
sleeves
over
2
5
4
Tools Needed:
7/16 in
7/16 in
802 456-A
OM-225 311 Page 12
. A complete Parts List is available on-line at www.MillerWelds.com
4-3. Work Cable Routing Inside Unit
2
1
2
Work Cable
Output Terminal Block
Insert work cable through opening
in front panel and route along back
of front panel to output terminal
block.
1
Close door.
Ref. 802 982-A
4-4. Process/Polarity Table
Cable Connections
Process
Polarity
Cable To Gun
Cable To Work
GMAW − Solid wire with shielding gas
DCEP − Reverse polarity
Connect to positive (+) output terminal
Connect to negative (−) output
terminal
FCAW − Self-shielding wire −
no shielding gas
DCEN − Straight Polarity
Connect to negative (−)
output terminal
Connect to positive (+) output
terminal
4-5. Changing Polarity
. Connection hardware must be tightened with proper tools. Do not
1
just hand tighten hardware. A loose electrical connection will cause
poor weld performance and excessive heating at the terminal block.
2
C H A N G IN G P O L A R IT Y
DCEP
Electrode
ElectrodePOSITIVE
Positive
FOR SOLID WIRE
WorkClamp
Lead
DCEN
Electrode Negative
Flux Core Wire
Always read and follow wire
manufacturer’s
recommended
polarity, and see Section 4-4.
Close door.
WorkClamp
Lead
1
Lead Connections For Direct
Current Electrode Positive
(DCEP)
Lead Connections For Direct
Current Electrode Negative
(DCEN)
2
Wire Drive
Lead
Wire Drive
Lead
Ref. 203 501 / Ref. 802 982-
OM-225 311 Page 13
. A complete Parts List is available on-line at www.MillerWelds.com
4-6. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
. DO NOT use Argon/Mixed gas regulator/flowmeter
with CO2 shielding gas. See Parts List for optional
CO2 gas regulator/flowmeter and hose.
1
4
1
Cap
2
Cylinder Valve
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
3
Cylinder
4
Regulator/Flowmeter
Install so face is vertical.
2
7
3
5
Regulator/Flowmeter Gas
Hose Connection
6
Welding Power Source Gas
Hose Connection
Connect supplied gas hose
between regulator/flowmeter gas
hose connection, and fitting on rear
of welding power source.
7
5
Flow Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire
manufacturer’s recommended flow
rate.
Argon Gas Or
Mixed Gas
6
Tools Needed:
5/8, 1-1/8 in
Ref. 802 028 / 802 441
OM-225 311 Page 14
. A complete Parts List is available on-line at www.MillerWelds.com
4-7. Selecting A Location And Connecting Input Power For 115 VAC Model
1
2
1
Rating Label
Grounded Receptacle
A 115 volt, 20 ampere individual
branch circuit protected by time-delay
fuses or circuit breaker is required.
18 in
(460 mm)
2
3
Plug From Unit
Select extension cord of 14 AWG
for up to 50 ft (15 m) or 12 AWG for
50 up to 200 ft (61 m).
3
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
18 in
(460 mm)
804 681-A
OM-225 311 Page 15
. A complete Parts List is available on-line at www.MillerWelds.com
4-8. Selecting A Location And Connecting Input Power For 230 VAC Model
Y Installation must meet all National and Local Codes − have
only qualified persons make
this installation.
Y Disconnect and lockout/tagout input power before connecting input conductors from
unit.
Y Do not move or operate unit
where it could tip.
Y Always connect green or
green/yellow conductor to
supply grounding terminal
first, and never to a line terminal.
1
18 in (457 mm) of
space for airflow
6
=GND/PE Earth
Ground
8
1
2
3
5
4
5
7
6
2
3
7
L1
L2
Rating Label
Supply correct input power.
Black And White Input
Conductor (L1 And L2)
Green Or Green/Yellow
Grounding Conductor
Input Power Cord.
Disconnect Device (switch
shown in the OFF position)
Disconnect Device Grounding
Terminal
Disconnect Device Line
Terminals
Connect green or green/yellow
grounding conductor to disconnect
device grounding terminal first.
4
Connect input conductors L1 and L2
to disconnect device line terminals.
8
1
Over-Current Protection
Select type and size of over-current
protection using Section 4-9 (fused
disconnect switch shown).
9
Close and secure door on disconnect
device. Remove lockout/tagout device, and place switch in the On position.
9 Plug (NEMA 6-50P)
10 Receptacle (NEMA 6-50R)
Connect plug to receptacle.
10
L1
L2
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
230 VAC, 1
Tools Needed:
Ref. 804 681-A / Ref. 802 443 / Ref. 802 085 / 803 766-B
OM-225 311 Page 16
. A complete Parts List is available on-line at www.MillerWelds.com
4-9. Electrical Service Guide For 230 VAC Model
60 Hz
Single
Phase
Input Voltage
230
Input Amperes At Rated Output
21.7
Max Recommended Standard Fuse Rating In Amperes
Min Input Conductor Size In AWG
Circuit Breaker 1, Time-Delay 2
25
Normal Operating 3
30
4
14
61
(19)
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
14
Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Y Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.
4-10. Installing Wire Spool And Adjusting Hub Tension
Installing 4 in (102 mm) Wire Spool
When a slight force is needed
to turn spool, tension is set.
Installing 8 in (203 mm) Wire Spool
Adapter used with
8 in (203 mm)
spool only.
When a slight force is needed
to turn spool, tension is set.
Retaining ring used
with 8 in (203 mm)
spool only.
Tools Needed:
1/2 in
803 012 / 803 013 -B / Ref. 802 444-C
OM-225 311 Page 17
. A complete Parts List is available on-line at www.MillerWelds.com
4-11. Threading Welding Wire
1
2
3
4
5
6
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Gun Conduit Cable
Lay gun cable out straight.
4
6
Tools Needed:
1
2
3
5
. Hold wire tightly to keep it
from unraveling.
4 in
(102 mm)
6 in
(150 mm)
Open pressure assembly.
Pull and hold wire; cut off end.
Push wire thru guides into gun;
continue to hold wire.
. Use pressure indicator scale to set a desired
drive roll pressure. Begin with a setting of 3.
If necessary, make additional adjustments
after trying this initial setting.
Tighten
1
2
3
4
Pressure
Indicator
Scale
INPUT
POWER
Be sure that wire is positioned in proper drive
roll groove and wire is laying in the groove.
Close and tighten pressure
assembly, and let go of wire.
Remove gun nozzle and contact tip.
Turn power on.
Tighten
WOOD
Press gun trigger until wire comes
out of gun.
Be sure that tip matches wire diameter.
Reinstall contact tip and nozzle.
1
2
3
4
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close door.
Ref. 802 982-A / Ref. 205 837
OM-225 311 Page 18
. A complete Parts List is available on-line at www.MillerWelds.com
4-12. Removing MIG Gun From Welding Power Source
Cut Off End Of Wire
Open Pressure Assembly
Knob
. Hold wire tightly to keep it
from unraveling.
Rewind Wire Onto Spool, Fasten
End Of Wire To Spool
Loosen Knob, Disconnect Gun Trigger
Plug, And Pull Gun From Unit
Ref. 802 982-A
OM-225 311 Page 19
. A complete Parts List is available on-line at www.MillerWelds.com
4-13. Installing Optional Spool Gun Switch In Welding Power Source
Y Turn Off unit, and disconnect
input power.
. For
1
units prior to Serial No.
LH210051N, use retrokit part
no. 234402 for installing spool
gun switch.
2
Remove wrapper from welding
power source.
1
2
1
Welding Power Source Center
Baffle
Snap-in Blank
Remove and discard snap-in blank
from hole in center baffle.
3
4
3
4
Switch Assembly
Star Washer
5
Jam Nut
Remove top jam nut and star washer from switch (switch is equipped
with two nuts, a jam nut and a
backing nut).
Insert switch assembly into center
baffle so that keyway in switch shaft
is facing up.
5
Secure switch to center baffle with
star washer and jam nut. Tighten
jam nut enough to keep switch from
rotating.
6
7
8
Wiring Harness Connectors
Switch Connectors
Label
Locate and separate connectors in
wiring harness near label.
Connect switch connectors to
matching connectors in wiring
harness.
Install wrapper on unit.
Operation:
Place switch in the position with the
spool gun symbol on the label for
spool gun operation. Place switch in
the position with the MIG gun symbol
on the label for wire feeder/MIG
(GMAW) gun operation.
When the switch is in the spool gun
position, spool gun wire feed speed
and voltage are controlled by
welding power source controls.
7
6
8
Tools Needed:
1/4, 5/16 in
9/16 in
Ref. 804 984-A / 804 892-A
OM-225 311 Page 20
. A complete Parts List is available on-line at www.MillerWelds.com
4-14. Connecting Spool Gun To Millermatic 140/180
6
1
2
3
4
7
Drive Assembly
Spool Gun
Gun Securing Knob
Gun End
Loosen thumbscrew. Insert end
through opening until it bottoms
against drive assembly. Tighten
gun securing knob.
Spool gun must be inserted
completely to prevent leakage of
shielding gas.
5
5
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
6
Spool Gun/MIG Gun Switch
Place switch in Spool Gun position.
7
1
3
4
To make proper polarity connection,
see welding power source Owner’s
Manual.
2
Close door.
. Be sure that gun end is tight against drive assembly.
4
Incorrect
Gun Not Seated
Exposed O-rings
will cause shielding
gas leakage.
Polarity Changeover Terminal
Block
4
Correct
Gun Fully Seated
804 984-A / Ref. 801 987
OM-225 311 Page 21
. A complete Parts List is available on-line at www.MillerWelds.com
SECTION 5 − OPERATION
5-1. Controls For 115 VAC Model w/Auto-SetE
1
6
2
3
5
4
227 748-C
1 Wire Speed Control
Turn control clockwise inside white scale
(10-100) to increase wire feed speed. (see
weld parameter chart in welding power
source or Section 5-4, 5-5, 5-6, 5-7, or 5-8
as applicable).
2 Voltage Control
Turn control clockwise inside white scale
(1-10) to increase voltage (see weld
parameter chart in welding power source
or Section 5-4, 5-5, 5-6, ,5-7, or 5-8 as
applicable).
OM-225 311 Page 22
3
Power Switch
4
Over Temperature Light
5
Gun Trigger Receptacle
6
Auto−Set™ Light
To use Auto−Set™ mode, rotate Wire
Speed control inside blue area for the
applicable
Weld
Wire
Diameter,
Auto−Set™ light will turn on, and the unit will
provide the appropriate wire feed speed for
the material thickness selected using the
Voltage control (see Section 5-4).
Rotate Voltage control inside blue scale (24
ga to 1/8”) for the applicable material
thickness and the unit will provide the
appropriate voltage within the range of the
selected material thickness and the selected
Weld Wire Diameter (see Section 5-4).
. A complete Parts List is available on-line at www.MillerWelds.com
5-2. Controls For 115 VAC Model
1
2
®
115VWireWelder
Welds24gaugeto3/16"MildSteel
V
ON
3
V
OFF
TRIGGER
OVERTEMP
POWER
5
4
225 226-C
1 Wire Speed Control
Turn control clockwise to increase wire
feed speed. (see weld parameter chart in
welding power source or Section 5-4, 5-5,
5-6, 5-7, or 5-8, as applicable).
2 Voltage Control
Turn control clockwise to increase voltage
(see weld parameter chart in welding
power source or Section 5-4, 5-5, 5-6, 5-7
or 5-8, as applicable).
3
Power Switch
4
Over Temperature Light
5
Gun Trigger Receptacle
OM-225 311 Page 23
. A complete Parts List is available on-line at www.MillerWelds.com
5-3. Controls For 230 VAC Model
1
2
230VWireWelder
Welds24gaugeto5/16"MildSteel
V
ON
3
V
OFF
TRIGGER
OVERTEMP
POWER
5
4
225 227-C
1 Wire Speed Control
Turn control clockwise to increase wire
feed speed. (see weld parameter chart in
welding power source or Section 5-5, 5-4,
5-6, 5-7 or 5-8, as applicable).
OM-225 311 Page 24
2 Voltage Control
Turn control clockwise to increase voltage
(see weld parameter chart in welding
power source or Section 5-5, 5-4, 5-6, 5-7
or 5-8 as applicable).
3
Power Switch
4
Over Temperature Light
5
Gun Trigger Receptacle
. A complete Parts List is available on-line at www.MillerWelds.com
Notes
OM-225 311 Page 25
. A complete Parts List is available on-line at www.MillerWelds.com
5-4. Weld Parameter Chart For 115 VAC Model w/Auto−SetE
Auto−Sett − SIMPLE SETUP FOR WELDING MILD STEEL
Example: .030” diameter wire, welding 18 ga. material.
.024”
.030”
t
Se
o−
ut
A
t
Auto−Set*
WELD WIRE
DIAMETER
MATERI AL TH
IC
KN
ES
S
Activate Auto−Sett by selecting
the diameter of the welding wire
with the WIRE SPEED knob.
Auto−Set light comes on.
Select thickness of the mild steel
being welded with the VOLTAGE
knob.
Setup complete.
(DCEP)
(DCEP)
(DCEN)
(DCEP)
Selecting Wire, Gas and Control Settings for Aluminum with optional Spool Gun. Order part no. 300371
Aluminum w/
Opt. Spool Gun
Aluminum
4043ER
100% Argon
.030” (0.8 mm)
.035” (0.9 mm)
NOTE: Settings are approximate. Adjust as required.
“−−−” Means not recommended.
“*” Thicker materials can be welded using proper technique,
joint preparation and multiple passes.
IMPORTANT: Match drive roll groove to diameter of wire being used.
Set Tension knob setting to 3 at start. Adjust tension
per instructions in the manual.
OM-225 311 Page 26
. A complete Parts List is available on-line at www.MillerWelds.com
Manual Setup
Refer to chart below to select Voltage and Wire Speed based
on thickness of metal being welded.
1. Number on right
of slash is Wire
Speed Knob Setting.
(Example: 4 / 65)
ATERI AL TH
t M
IC
et
KN
−S
E
o
SS
ut
A
2. Number on left of
slash is Voltage
Knob Setting.
(Example: 4 / 65)
4.5/70 5.5/80 10/90
2/40
3/50
3/50
4/65
2/32
3/40
3/40
4/45
5/55
4/45
5/60
5.5/65
4/35
5/40
5.5/45 6.5/50 10/60
5.5/60 10/65
7/80
10/80
2/35
3/40
5.5/60 10/65
2.5/32
3/35
4.5/45 10/50
4.5/50 4.5/50
6/75
7/95
10/95
5/50
6/60
7/70
10/75
3/90
3/70
3/90
3/75
10/100
10/90
4/40
10/50
H
227 931-H
OM-225 311 Page 27
. A complete Parts List is available on-line at www.MillerWelds.com
5-5. Weld Parameter Chart For 115 VAC Model w/Factory Set
Non-Wire Speed Tracking Mode
Refer to chart below to select Voltage and Wire Speed based on
thickness of material being welded.
1. Number on left of
2. Number on right
slash is Voltage
of slash is Wire
Knob Setting.
(Example: 4.5 / 65)
Speed Knob Setting.
(Example: 4.5 / 65)
Solid Wire
ER70S−6
(DCEP)
Solid Wire
ER70S−6
(DCEP)
Flux Core
E71T−11
(DCEN)
Stainless
Steel
(DCEP)
Selecting Wire, Gas and Control Settings for Aluminum
Aluminum w/
Opt. Spool Gun
OM-225 311 Page 28
Aluminum
4043ER
100% Argon
.030” (0.8 mm)
.035” (0.9 mm)
. A complete Parts List is available on-line at www.MillerWelds.com
NOTE: Settings are approximate. Adjust as required.
“−−−” Means not recommended.
“*” Thicker materials can be welded using proper technique,
joint preparation and multiple passes.
IMPORTANT: Match drive roll groove to diameter of wire being used.
Set Tension knob setting to 3 at start. Adjust tension
per instructions in the manual.
2.5/35
2.5/28
3.5/45
3/30
3.5/45
3/30
4.5/35
5/22
5/40
5/30
4/55
4.5/40
5.5/45
5.5/30
2/30
2/25
6/50
5/35
4.5/65
5/45
5.5/55
6/35
3.5/40
3.5/25
6.5/70
6/60
5.5/80
5.5/50
8/65
6.5/40
5.5/50
6/40
7.5/85
7/70
10/90
10/45
10/60
10/30
10/45
8/40
10/80
10/60
10/32
with optional Spool Gun, Order part no. 300371
2/60
3/60
3/70
3.5/65
10/75
10/70
224 940−D
224 940-D
OM-225 311 Page 29
. A complete Parts List is available on-line at www.MillerWelds.com
5-6. Weld Parameter Chart For 115 VAC Model w/Wire Speed Tracking Mode
Refer to chart below to select Voltage and Wire Speed based on
thickness of material being welded.
1. Number on left of
2. Number on right
slash is Voltage
of slash is Wire
Knob Setting.
(Example: 4.5/65)
Speed Knob Setting.
(Example: 4.5 / 65)
Solid Wire
ER70S−6
(DCEP)
Solid Wire
ER70S−6
(DCEP)
Flux Core
E71T−11
(DCEN)
Stainless
Steel
(DCEP)
To enable wire speed tracking, proceed as follows:
1. Turn Power switch off.
2. Rotate Voltage knob to minimum.
3. Rotate Wire Speed knob to maximum.
4. Hold gun trigger in while turning on Power switch.
. To verify wire speed tracking is on, open drive roll pressure arm, pull trigger,
and rotate Voltage knob from min. to max. Drive roll speed will change rpm
if tracking is on.
OM-225 311 Page 30
. A complete Parts List is available on-line at www.MillerWelds.com
NOTE: Settings are approximate. Adjust as required.
“−−−” Means not recommended.
“*” Thicker materials can be welded using proper technique,
joint preparation and multiple passes.
IMPORTANT: Match drive roll groove to diameter of wire being used.
Set Tension knob setting to 3 at start. Adjust tension
per instructions in the manual.
2.5/35
2.5/28
3.5/45
3/30
3.5/45
3/30
4.5/35
5/22
5/40
5/30
4/55
4.5/40
5.5/45
5.5/30
2/30
2/25
6/50
5/35
4.5/65
5/45
5.5/55
6/35
3.5/40
3.5/25
6.5/70
6/60
5.5/80
5.5/50
8/65
6.5/40
5.5/50
6/40
7.5/85
7/70
10/90
10/45
10/60
10/30
10/45
8/40
10/80
10/60
10/32
232 016-A
To disable wire speed tracking, proceed as follows:
1. Turn Power switch off.
2. Rotate Voltage knob to maximum.
3. Rotate Wire Speed knob to minimum.
4. Hold gun trigger in while turning on Power switch.
. To verify wire speed tracking is off, open drive roll pressure arm, pull trigger,
and rotate Voltage knob from min. to max. Drive roll speed will have minimal
change in rpm if tracking is off.
232 016-A
OM-225 311 Page 31
. A complete Parts List is available on-line at www.MillerWelds.com
5-7. Weld Parameter Chart For 230 VAC Model w/Factory Set
Non-Wire Speed Tracking Mode
Refer to chart below to select Voltage and Wire Speed based on
thickness of material being welded.
1. Number on left of
2. Number on right
slash is Voltage
of slash is Wire
Knob Setting.
Speed Knob Setting.
(Example: 4.5 / 55)
(Example: 4.5 / 55)
(DCEP)
(DCEP)
(DCEN)
Stain− Stainless
less
Steel
Steel (DCEP)
Selecting Wire, Gas and Control Settings for Aluminum
.030” (0.8 mm)
100% Argon
Aluminum Aluminum
4043ER
.035” (0.9 mm)
Spool Gun
.024”
.030”
.035”
.045”
OM-225 311 Page 32
(0.6
(0.8
(0.9
(1.2
mm)
mm)
mm)
mm)
#087299
#000067
#000068
#000069
.024”
(0.6 mm)
#194010
.030 − .035” (0.8 − 0.9 mm) #194011
.035 − .045” (0.9 − 1.2 mm) #194012
. A complete Parts List is available on-line at www.MillerWelds.com
NOTE: Settings are approximate. Adjust as required.
“−−−” Means not recommended.
Thicker materials can be welded using proper technique,
joint preparation and multiple passes.
IMPORTANT: Match drive roll groove to diameter of wire being used. Set Tension
knob setting to 3 at start. Adjust tension per instructions in the manual.
1.5/20
1.5/15
2/25
2/20
2/12
3/45
3/35
3/25
4/40
4/25
4/20
2/20
2/15
2.5/10
3.5/30 3.5/45 4/50
3.5/25 3.5/28 4/45
2.5/20 3.5/25
2/25
2/20
2/15
3.5/25
3/15
2.5/30
2.5/30
2.5/20
3.5/25
3.5/20
3/12
1/15
1/10
3.5/60
3.5/40
3.5/30
4.5/50
4.5/35
4.5/30
3.5/35
3/25
3/15
4.5/70
5/60
4/40
4/70 6/100
6/80 10/95
4.5/55 6/75
4.5/45 6/55 6.5/60 10/70
5/60
7/85
5.5/45 6/55 6.5/65 10/75
5.5/35 6/40 6.5/50 10/55
4/45
6/65 6.5/75
4/35
7/60 10/65
6/55
4/25
6/35
7/40 10/45
5/80
6/95
5/70
6/85 7.5/95
4.5/50 6/65 7.5/80
with optional Spool Gun, Order part no. 300371
2/70
2/70
2.5/65
.024” (0.6 mm)
.030” (0.8 mm)
.035” (0.9 mm)
.045” (1.2 mm)
4/70
4/60
#220179
#220179
#220179
5/70
5/65
#202926
#202926
#202926
8/95
8/90
10/100
10/90
225 229−F
225 229-F
OM-225 311 Page 33
. A complete Parts List is available on-line at www.MillerWelds.com
5-8. Weld Parameter Chart For 230 VAC Model w/Wire Speed Tracking Mode
Refer to chart below to select Voltage and Wire Speed based on
thickness of material being welded.
1. Number on left of
slash is Voltage
Knob Setting.
(Example: 4.5 / 65)
2. Number on right
of slash is Wire
Speed Knob Setting.
(Example: 4.5 / 65)
(DCEP)
(DCEP)
(DCEN)
(DCEP)
.024” (0.6 mm) #087299
.030” (0.8 mm) #000067
.035” (0.9 mm) #000068
.045” (1.2 mm) #000069
.024”
(0.6 mm)
#194010
.030 − .035” (0.8 − 0.9 mm) #194011
.035 − .045” (0.9 − 1.2 mm) #194012
.035 − .045” (0.9 − 1.2 mm) #194012
To enable wire speed tracking, proceed as follows:
1. Turn Power switch off.
2. Rotate Voltage knob to minimum.
3. Rotate Wire Speed knob to maximum.
4. Hold gun trigger in while turning on Power switch.
. To verify wire speed tracking is on, open drive roll pressure arm, pull trigger,
and rotate Voltage knob from min. to max. Drive roll speed will change rpm
if tracking is on.
OM-225 311 Page 34
. A complete Parts List is available on-line at www.MillerWelds.com
NOTE: Settings are approximate. Adjust as required.
“−−−” Means not recommended.
“*” Thicker materials can be welded using proper technique,
joint preparation and multiple passes.
IMPORTANT: Match drive roll groove to diameter of wire being used. Set Tension
knob setting to 3 at start. Adjust tension per instructions in the manual.
2/22
2.5/28 2.5/28
3/30
3.5/45
4/50
3.5/30
4/35
4.5/40
2.5/15 2.5/15 3.5/20
4/25
4.5/30 4.5/35
3.5/20 3.5/25
4/40
4.5/40
4/10
4.5/20
5/25
4/10
4/18
5/20
5/25
6/25
6/35
1/15
2/20
3/30
4/40
5.5/50
7/60
1/15
2/20
3/20
4/35
6/45
6.5/55 10/40
2/10
3/15
4/20
6/30
6.5/30 10/20
2.5/10 2.5/15
3/20
3.5/10
4.5/70 7/100
5/50
5/50
5.5/60 6.5/70 10/60
6/50
5.5/65
5.5/35 6.5/40 7.5/50
4/25
4/40
5/45
5/65
5/70
6/85
4/10
4/20
4/25
4/30
4.5/45
5/50
3.5/15
4/25
4.5/40
5/40
.024” (0.6 mm)
.030” (0.8 mm)
.035” (0.9 mm)
.045” (1.2 mm)
#220179
#220179
#220179
6.5/55 10/45
5.5/60
5.5/55 10/50
#202926
#202926
#202926
232 017-A
To disable wire speed tracking, proceed as follows:
1. Turn Power switch off.
2. Rotate Voltage knob to maximum.
3. Rotate Wire Speed knob to minimum.
4. Hold gun trigger in while turning on Power switch.
. To verify wire speed tracking is off, open drive roll pressure arm, pull trigger,
and rotate Voltage knob from min. to max. Drive roll speed will have minimal
change in rpm if tracking is off.
232 017-A
OM-225 311 Page 35
. A complete Parts List is available on-line at www.MillerWelds.com
SECTION 6 − MAINTENANCE &TROUBLESHOOTING
6-1. Routine Maintenance
. Maintain more often
Y Disconnect power
before maintaining.
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
during severe conditions.
l = Replace
Reference
Every
3
Months
l Unreadable Labels
Every
6
Months
~ Weld Terminals
nl Weld Cables
OR
~ Inside Unit
6-2. Overload Protection
1
Supplementary Protector CB1
CB1 protects unit from overload. If
CB1 opens, unit shuts down.
1
Reset supplementary protector.
802 441
6-3. Drive Motor Protection And Tip Saver/Short Circuit Protection
A. Drive Motor Protection
Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, cycle unit power
off and back on again.
B. Tip Saver/Short Circuit Protection
The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contact
tip is shorted to workpiece, the unit shuts down the welding output, but the fan continues to run. To resume operation,
release gun trigger to reset unit. If the contact tip has stuck to the workpiece, release gun trigger, turn off unit, and
remove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue operation.
OM-225 311 Page 36
. A complete Parts List is available on-line at www.MillerWelds.com
6-4. Changing Drive Roll Or Wire Inlet Guide
1
Inlet Wire Guide
Remove guide by pressing on
barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.
2
1
2
3
Stamped .024
Retaining Pin
To secure drive roll, locate open slot
and push drive roll completely over
retaining pin, then rotate drive roll
1/4 turn to closed slot.
3
.030/.035 Groove
Drive Roll
The drive roll consists of two different sized grooves. The stamped
markings on the end surface of the
drive roll refers to the groove on the
opposite side of the drive roll. The
groove closest to the motor shaft is
the proper groove to thread (see
Section 4-11).
.024 Groove
Stamped .030/.035
802 984
6-5. Replacing Gun Contact Tip
Y Turn Off power before
replacing contact tip.
1
2
Nozzle
Contact Tip
Cut off welding wire at contact tip.
Remove nozzle.
Remove contact tip and install new
contact tip. Reinstall nozzle.
2
1
Tools Needed:
Ref. 802 399-A
OM-225 311 Page 37
. A complete Parts List is available on-line at www.MillerWelds.com
6-6. Cleaning Or Replacing Gun Liner
Tools Needed:
Y Disconnect gun from unit.
8 mm / 10 mm
Head Tube
Remove nozzle, contact tip,
adapter, gas diffuser, and wire
outlet guide.
8 mm
10 mm
Remove liner.
Lay gun cable out straight
before installing new liner.
To Reassemble Gun:
Install and tighten new liner.
Blow out gun casing.
Cut liner off 3/4 in (20 mm) (3/8 in
[9.5 mm] for aluminum) from head
tube.
Install adapter, contact tip, and
nozzle.
Ref. ST-802 399-A
OM-225 311 Page 38
. A complete Parts List is available on-line at www.MillerWelds.com
6-7. Replacing Switch And/Or Head Tube
Y Turn Off welding power source
/wire feeder and disconnect gun.
1
Remove handle
locking nut.
3
2
Slide handle.
Remove switch housing. Install new switch and
connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube,
continue to end of figure.
4 Secure head
tube in vice.
5
6
Loosen jam nut.
Remove from vice
and turn head tube
out by hand.
Hand-tighten head tube into cable connector.
8
7
Place head tube in vice and tighten until
nuts are tight.
Remove from vice. Reposition handle and install
switch housing. Secure with handle locking nut.
Tools Needed:
19 mm
Ref. ST-800 795-C
OM-225 311 Page 39
. A complete Parts List is available on-line at www.MillerWelds.com
6-8. Troubleshooting Table
Trouble
Remedy
No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 4-7 or 4-8).
does not run.
Replace building line fuse or reset circuit breaker if open.
Place Power switch in On position (see Section 5-2, 5-1, or 5-3).
Reset welding power source supplementary protector if open.
No weld output; wire does not feed; fan Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when
unit has cooled (see Section 6-3).
motor continues to run.
Secure gun trigger plug (see Section 4-1).
Release gun trigger and cycle unit power off and back on again.
No weld output; wire feeds.
Connect work clamp to get good metal to metal contact.
Replace contact tip (see Section 6-5).
Check for proper polarity connections (see Section 4-5).
Check thumbscrew securing gun end to feed head adapter and tighten if necessary.
Low weld output.
Connect unit to proper input voltage or check for low line voltage.
Place Power switch in On position (see Section 5-2, 5-1, or 5-3).
Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts.
welding.
Adjust drive roll pressure (see Section 4-11).
Change to proper drive roll groove (see Section 6-4).
Readjust hub tension (see Section 4-10).
Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove.
Replace contact tip if blocked (see Section 6-5). Oversized tip may be required for some wires.
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 6-4 or Section 6-6).
Replace drive roll or pressure bearing if worn or slipping (see Section 6-4).
Secure gun trigger plug (see Section 4-1).
Check and clear any restrictions at drive assembly and liner (see Section 6-4 or Section 6-6).
Release gun trigger and allow gun and motor protection circuitry to reset.
Have nearest Factory Authorized Service Agent check drive motor.
OM-225 311 Page 40
Notes
OM-225 311 Page 41
SECTION 7 − ELECTRICAL DIAGRAM
Figure 7-1. Circuit Diagram
OM-225 311 Page 42
234 419-B
OM-225 311 Page 43
SECTION 8 − MIG WELDING (GMAW) GUIDELINES
8-1. Typical MIG Process Connections
Y Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Regulator/
Flowmeter
Wire Feeder/
Power Source
Shielding Gas
Gas Hose
Gun
Work Clamp
Workpiece
light mig 5/967 / Ref. 802 982-A
OM-225 311 Page 44
8-2. Typical MIG Process Control Settings
NOTE
These settings are guidelines only. Material and wire type, joint design, fitup,
position, shielding gas, etc. affect settings. Test welds to be sure they comply to
specifications.
Material thickness determines weld
parameters.
1/8 or
.125 in
Convert Material
Thickness to
Amperage (A)
(.001 in = 1 ampere)
.125 in = 125 A
.035 in
Wire Size
Amperage Range
.023 in
30 − 90 A
.030 in
.035 in
40 − 145 A
50 − 180 A
Select Wire Size
Wire
Size
Recommendation
Wire Speed
(Approx.)
Select Wire Speed
(Amperage)
.023 in
.030 in
.035 in
3.5 in per ampere
2 in per ampere
1.6 in per ampere
3.5 x 125 A = 437 ipm
2 x 125 A = 250 ipm
1.6 x 125 A = 200 ipm
125 A based on 1/8 in
material thickness
ipm = inch per minute
Low voltage: wire stubs into work
High voltage: arc is unstable (spatter)
Select Voltage
Set voltage midway between high/low voltage.
Wire speed (amperage) controls weld penetration
(wire speed = burn-off rate)
Voltage controls height and width of
weld bead.
Ref. 804 681-A
OM-225 311 Page 45
8-3. Holding And Positioning Welding Gun
NOTE
Welding wire is energized when gun trigger is pressed. Before lowering helmet and
pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.
1
1
3
2
2
3
4
5
Hold Gun and Control Gun
Trigger
Workpiece
Work Clamp
Electrode Extension (Stickout)
1/4 to 1/2 in (6 To 13 mm)
Cradle Gun and Rest Hand on
Workpiece
5
4
0°-15°
90°
90°
End View Of Work Angle
Side View Of Gun Angle
GROOVE WELDS
0°-15°
45°
45°
End View Of Work Angle
Side View Of Gun Angle
FILLET WELDS
OM-225 311 Page 46
S-0421-A
8-4. Conditions That Affect Weld Bead Shape
NOTE
Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.
10°
Push
Perpendicular
10°
Drag
GUN ANGLES AND WELD BEAD PROFILES
Short
Normal
Long
ELECTRODE EXTENSIONS (STICKOUT)
Short
Normal
Long
FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)
Slow
Normal
GUN TRAVEL SPEED
Fast
S-0634
OM-225 311 Page 47
8-5. Gun Movement During Welding
NOTE
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads works better.
1
1
2
2
3
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side To Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
3
S-0054-A
8-6. Poor Weld Bead Characteristics
1
2
3
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
5
S-0053-A
8-7. Good Weld Bead Characteristics
1
2
3
1
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in (3.2 mm) thickness in metals
being welded.
4
5
2
3
4
No Overlap
Good Penetration into Base
Metal
5
S-0052-B
OM-225 311 Page 48
8-8. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.
S-0636
Possible Causes
Corrective Actions
Wire feed speed too high.
Select lower wire feed speed.
Voltage too high.
Select lower voltage range.
Electrode extension (stickout) too long.
Use shorter electrode extension (stickout).
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
Wrong polarity.
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s
recommended polarity, and see Section 4-5.
8-9. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Insufficient shielding gas at welding arc.
Corrective Actions
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas.
Use welding grade shielding gas; change to different gas.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Wrong polarity.
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s
recommended polarity, and see Section 4-5.
OM-225 311 Page 49
8-10. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
S-0639
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
Wrong polarity.
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s
recommended polarity, and see Section 4-5.
8-11. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow
fusion between weld metal and
base metal.
Lack of Penetration
Good Penetration
S-0638
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Improper weld technique.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Insufficient heat input.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
Wrong polarity.
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s
recommended polarity, and see Section 4-5.
8-12. Troubleshooting − Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
S-0637
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input.
Select higher voltage range and/or adjust wire feed speed.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
Wrong polarity.
OM-225 311 Page 50
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s
recommended polarity, and see Section 4-5.
8-13. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.
S-0640
Possible Causes
Corrective Actions
Excessive heat input.
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
Wrong polarity.
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s
recommended polarity, and see Section 4-5.
8-14. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Possible Causes
Corrective Actions
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Unsteady hand.
Support hand on solid surface or use two hands.
8-15. Troubleshooting − Distortion
Distortion − contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642
Possible Causes
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-225 311 Page 51
8-16. Common MIG Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.
Application
Gas
Spray Arc Steel
Short Circuiting Steel
Short Circuiting
Stainless Steel
Argon
All Positions
Argon + 25% CO2
Flat & Horizontal1 Fillet
All Positions
CO2
Flat & Horizontal1 Fillet
All Positions
Tri-Mix3
1
Globular Transfer
2
Single Pass Welding Only
3
90% HE + 7-1/2% AR + 2-1/2% CO2
OM-225 311 Page 52
Short Circuiting
Aluminum
All Positions2
All Positions
SECTION 9 − PARTS LIST
9-1. Recommended Spare Parts
Item
No.
Part
No.
. . . . . . . . . . . . . . . . . . . . . 169 715
. . . . . . . . . . . . . . . . . . . ♦087 299
. . . . . . . . . . . . . . . . . . . ♦000 067
. . . . . . . . . . . . . . . . . . . ♦000 068
. . . . . . . . . . . . . . . . . . . ♦000 069
. . . . . . . . . . . . . . . . . . . ♦194 010
. . . . . . . . . . . . . . . . . . . ♦194 011
. . . . . . . . . . . . . . . . . . . ♦194 012
. . . . . . . . . . . . . . . . . . . . . 079 975
Description
Quantity
. . NOZZLE, slip type .500 orf flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TIP, contact scr .023 wire x 1.125
. . TIP, contact scr .030 wire x 1.125
. . TIP, contact scr .035 wire x 1.125
. . TIP, contact scr .045 wire x 1.125
. . LINER, monocoil .023/.025 wire x 15ft (consisting of) . . . . . . . . . . . . . . .
. . LINER, monocoil .030/.035 wire x 15ft (consisting of) . . . . . . . . . . . . . . .
. . LINER, monocoil .035/.045 wire x 15ft (consisting of) . . . . . . . . . . . . . . .
. . . . O-RING, .187 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
9-2. Optional Drive Rolls
For All Feed Head Assemblies
PART NO.
WIRE DIAMETER INCHES (mm)
220 179
.024 (.6) and .030 − .035 (.8 and .9)
202 926
.030/.035 (.8 and .9) and .045 (1.2 VK Groove)
9-3. Options
PART NO.
DESCRIPTION
REMARKS
770 187
Running Gear/Cylinder Rack
For One Small Gas Cylinder, 100 lb (45 kg)
194 776
Small Running Gear/Cylinder Rack
For One Small Gas Cylinder, 75 lb (34 kg)
195 605
M-10 Replacement Gun
10 ft length/.030-.035 wire size
. A complete Parts List is available on-line at www.MillerWelds.com
OM-225 311 Page 53
Notes
Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller 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 time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
5 Years Parts — 3 Years Labor
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
*
*
3.
Original main power rectifiers
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly 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 INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL 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, at 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
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement 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 CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
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,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations 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 specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that 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 vary from province to province.
miller_warr 2007−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
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
© 2007 Miller Electric Mfg. Co. 2007−01
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com