Miller | Millermatic 252 | User manual | Miller Millermatic 252 User manual

Millermatic 252
Issued Sept. 2008 • Index No. DC/12.49
®
Quick
Specs
Industrial Applications
Processes
Metal Fabrication
Maintenance and Repair
Farm/Home
Light Industrial
MIG (GMAW)
Flux Cored (FCAW)
Input Power
200(208)/230 V
230/460/575 V
MIG Arc Welding
Power Source
Rated Output
200 Amps at 28 VDC, 60% Duty Cycle
250 Amps at 28 VDC, 40% Duty Cycle
Max. Open-Circuit Voltage 38
Amperage Range 30 – 300 A
Wire Feed Speed 50 – 700 IPM (1.3 – 17.8 m/min)
Weight 207 lb (94 kg)
The Power of Blue .
®
Comes Complete With:
10 ft (3 m) power cord and plug
(200/230 V model only)
15 ft (4.6 m), 250 amp M-25 MIG gun
for .030/.035 in wire
10 ft (3 m) work cable and clamp
Argon mix regulator/flow gauge and hose
Extra contact tips
Factory-installed running gear with
EZ-Change™ Low Cylinder Rack
.030/.035 in reversible drive rolls
Set-up and operation interactive CD
Highest output in its class (250 A at 28 VDC).
Weld longer on high end applications.
Large, digital front panel with
built-in digital timers menu enables
operator to preset voltage and wire feed
speed. Standard run-in, pre/postflow,
burnback, spot/delay (stitch) timer menu.
Auto Gun Detect™ allows operator to
simply pull trigger on MIG gun, spool
gun or push/pull gun. Automatically
detects and recalls the voltage, wire
feed speed and timer of the active gun.
See page 3 for more information.
EZ-Access™ Consumable Compartment and
Parameter Chart — set weld parameters right
the first time with convenient new flip-down
compartment that provides fast access to
parameter chart and consumables. See page 3
for more information.
Push-Pull Gun Direct Connect — now
directly connects your push-pull gun,
no extra module required.
Angled, dual-gear driven, cast
aluminum drive system features
no-tool, quick-change reversible drive
rolls and an easy-to-set, scaled tension
knob. See page 3 for more information.
Patent-pending EZ-Change™ Low
Cylinder Rack allows operators to easily
roll cylinders on and off of rack — no
need to lift cylinders. See page 3 for
more information.
Larger work area —
now with longer
15-ft M-25 gun.
Fan-On-Demand™ cooling system only operates
when needed, reducing power consumption
and contaminants drawn into the machine.
Less weld cleanup with Active Arc Stabilizer ™
— patented Miller design provides excellent
starts proven superior to the competition.
Line voltage compensation keeps power
constant even if power input varies by ±10%.
Welder is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
Gun warranted for 90 days, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
Rated Output
200 A, 28 VDC
at 60%
Duty Cycle
(Subject to change without notice.)
Amperage
Range
Max.
OpenCircuit
Voltage
30 –300 A
38
Amps Input at Rated Output, 60 Hz
200(208) V 230 V 460 V 575 V KVA
48
2.3*
42
2*
21
1*
17
0.8*
KW
9.8 7.5
0.46* 0.13*
250 A, 28 VDC
at 40%
Duty Cycle
Wire Type and
Diameter
Wire Feed
Speed
Solid/Stainless
Steel:
.023 – .045 in
(0.6 – 1.2 mm)
50 –700 IPM
(1.3 –17.8
m/min)
Max.
Spool
Size
Dimensions
Net
Weight
12 in
(305 mm)
H: 30 in
(762 mm)
207 lb
(94 kg)
W: 19 in
(483 mm)
Flux Cored:
.030 – .045 in
(0.8 – 1.2 mm)
D: 40 in
(1016 mm)
*While idling.
Note: Operating Temperature Range: -4˚ to +104˚ F (-20 to +40˚ C) Storage Temperature Range: -22˚ to +122˚ F (-30 to +50˚ C)
Control Panel
1
3
2
4
1. Voltmeter
2. Voltage Control
3. Wire Speed Meter
4. Wire Speed Control
Performance Data
VOLT/AMP CURVES
35
250
25
30
200
VOLTS
WELD AMPS
DUTY CYCLE CHART
500
450
400
350
300
150
100
20
15
10
5
50
10
0
20
30
40
% DUTY CYCLE
2
50
60
70
80 90 100
0
100
200
AMPERES
300
400
Standard Fully Loaded Features
EZ-Change™ Low Cylinder Rack
Patent-pending design — operators
no longer need to lift cylinders. Cylinders
now easily roll on and off our EZ-Change™
Low Cylinder Rack.
Angled Wire Drive
Angled industrial aluminum dual-gear
drive system significantly improves
wirefeeding and runs large spools of wire.
Allows quick change of drive rolls
without tools.
Drive roll storage — no more lost drive
rolls, extra drive rolls are conveniently
stored next to drive motor.
Operators no longer bump into and bend
MIG gun and gun liner.
Dual Front Handles
Exclusive split handle with rubber grips
designed to move machine easily and
allow work lead and MIG gun to be
stored independently.
Handles provide protection for front panel
and MIG gun during transportation.
EZ-Access™ Consumable
Compartment and Parameter Chart
Convenient flip-down compartment
holds parameter chart and storage for
consumables.
Auto-Gun Detect™
Simply pull the trigger for either the MIG,
spool gun or any Miller push-pull gun.
The Millermatic 252 automatically recalls
voltage, wire feed speed and timer of the
active gun.
Reduces setup time!
3
Optional Fully Loaded Features
Elevated Gun and Cable Rack
#300 335
Tangle-free, independent way to store
spool gun cables, keeping them off of
the floor.
No more running over spool gun cables
or cables dragging on the floor.
Elevated Gun and Cable Rack can be
used with either a single or dual cylinder
rack. (Elevated Gun and Cable Rack is
included with the Dual EZ-Change™ Low
Cylinder Rack.)
Dual EZ-Change™ Cylinder Rack
with Elevated Gun and Cable Rack
#300 337
Dual cylinder rack allows for easy
storage for two cylinders.
EZ-Change™ Low Cylinder rack eliminates
the need to lift cylinders on and off
cylinder rack.
No more running over spool gun cables
or cables dragging on the floor.
Tangle-free, independent way to store
spool gun cables, keeping them off of
the floor.
4
Genuine Miller Accessories
Direct connection for all Miller
push-pull guns.
Able to utilize 12 in rolls of aluminum
wire inside the Millermatic 252 for
extended aluminum welding time.
Wire feed speed is adjustable at the gun
and actual speed can be seen on the
digital display on the Millermatic 252.
Adjustable run-in control to fine tune
arc starting.
XR-A Aluma-Pro Gun
#300 000 15 ft (4.6 m) Cable
#300 001 25 ft (7.6 m) Cable
300 amps at 100% duty cycle.
U-Groove Aluminum Drive Roll
and Accessory Kits
Note: XR-A Pistol kits include U-groove machine drive
rolls, nylon wire guides, gun drive rolls and contact tips.
XR-A Python/Aluma-Pro kits include U-groove machine
drive rolls, nylon wire guides and contact tips.
For XR-A Pistol
#195 201 .035 in (0.9 mm)
#195 273 .040 in (1 mm)
#195 202 .047 in (1.2 mm)
For XR-A Python/Aluma-Pro
#195 311 .035 in (0.9 mm)
#195 312 .040 in (1 mm)
#195 313 .047 in (1.2 mm)
M-25 Replacement Gun
#169 594 10 ft (3 m)
#169 596 12 ft (3.7 m)
#169 598 15 ft (4.6 m) standard
Gun shipped to run .030 –.035 in
(0.8 – 0.9 mm) wire.
Dual EZ-Change™ Low Cylinder Rack with
Elevated Gun and Cable Rack #300 337
Dual cylinder rack allows operators to
easily roll cylinders on and off the rack with
no lifting. Gun and cable rack keeps cables
off the floor and tangle free.
Elevated Gun and Cable Rack #300 335
For use with single cylinder rack. (Included
with Dual EZ-Change Low Cylinder Rack.)
XR-A Pistol Gun
#198 127 15 ft (4.6 m) Cable
#198 128 30 ft (9 m) Cable
200 amps at 100% duty cycle.
Spoolmatic® 15A Spool Gun #195 156
Spoolmatic® 30A Spool Gun #130 831
Ideal for aluminum welding jobs. 200 amp,
100% duty cycle, air-cooled, 1 lb spool
gun with your choice of 15 ft or (4.6 m)
30 ft (9.1 m) cable assembly. For detailed
information, see Spoolmatic literature,
Index No. M/1.2.
Protective Cover with Helmet Bag
#195 142
Features side pocket and helmet bag.
(Not for use with Dual Cylinder Rack or
Elevated Gun and Cable Rack.)
Argon/Mixed Gas Regulator and Gas Hose
#195 050
(Order from Miller Service Parts.)
CO2 Regulator/Flow Gauge #237 702
Required if using 100% CO2 gas.
(Order from Miller Service Parts.)
5
Consumables
(Order from Miller Service Parts.)
For M-25 Gun
Contact Tips
#087 299 .023/.025 in (0.6 mm)
#000 067 .030 in (0.8 mm)
#000 068 .035 in (0.9 mm)
#000 069 .045 in (1.2 mm)
#187 117 .035 in (0.9 mm) heavy-duty tip
#187 118 .045 in (1.2 mm) heavy-duty tip
Tapered Contact Tips
#176 797 .030 in (0.8 mm)
#176 793 .035 in (0.9 mm)
#176 794 .045 in (1.2 mm)
Contact Tip Adapter #169 728
Nozzles
Note: Flush or stickout nozzles should be used for
the short-circuit process. Recessed nozzles should be
used for the spray arc process.
#200 258 Standard
1/2 in (13 mm) diameter orifice. Nozzle
flush with contact tip.
#169 726
5/8 in (16 mm) diameter orifice.
Nozzle flush with contact tip.
#169 727
5/8 in (16 mm) diameter orifice. Contact tip
sticks out of nozzle 1/8 in (3.2 mm).
Replacement Liners
#194 010 .023/.025 in
#194 011 .030 –.035 in (standard)
#194 012 .035 –.045 in
#169 724
1/2 in (13 mm) diameter orifice. Contact tip
recessed 1/8 in (3.2 mm) into nozzle.
#169 725
5/8 in (16 mm) diameter orifice. Contact tip
recessed 1/8 in (3.2 mm) into nozzle.
Spot Nozzles
#176 238 Flat
#176 240 Inside corner
#176 242 Outside corner
Tapered Nozzles
Note: Tapered tips are recommended when using a
tapered nozzle.
#176 243 3/8 in (9.5 mm) diameter orifice
#178 386 11/32 in (8.7 mm) diameter orifice
6
Consumable Kits
#234 610 .030 in (0.8 mm)
#234 611 .035 in (0.9 mm)
#234 612 .045 in (1.2 mm)
Contains 10 contact tips, 1 nozzle,
1 contact tip adapter, and 1 nozzle adapter.
Drive Rolls
Note: Drive roll kits include two drive rolls and an
inlet guide.
V-Grooved Drive Roll Kits (solid wire)
#204 579 .030 & .035 in (0.8 & 0.9 mm)
Combination (Reversible)
#087 131 .023/.025 in (0.6 mm)
#079 594 .030 in (0.8 mm)
#079 595 .035 in (0.9 mm)
#079 596 .045 in (1.2 mm)
V-Knurled Drive Roll Kits
(Flux Cored or difficult-to-feed wire)
#079 606 .035 in (0.9 mm)
#079 607 .045 in (1.2 mm)
Ordering Information
Steel Configuration
Millermatic 252
®
V-Groove Drive Roll Kits (solid wire)
V-Knurled Drive Roll Kits (flux cored)
Contact Tips (10 per package)
Nozzles
Stock No.
Description
Qty.
#907 321
#907 322
#087 131
#079 594
#079 595
#079 596
#079 606
#079 607
#087 299
#000 067
#000 068
#000 069
#169 724
#169 725
#200 258
#169 726
#169 727
200(208)/230 V, 60 Hz
230/460/575 V, 60 Hz
.023/.025 (0.6 mm)
.030 (0.8 mm)
.035 (0.9 mm)
.045 (1.2 mm)
.035 (0.9 mm)
.045 (1.2 mm)
.023/.025 (0.6 mm)
.030 (0.8 mm)
.035 (0.9 mm)
.045 (1.2 mm)
1/2 in (13 mm) diameter, 1/8 in (3.2 mm) recessed
5/8 in (16 mm) diameter, 1/8 in (3.2 mm) recessed
1/2 in (13 mm) diameter, flush. Included with standard configuration
5/8 in (16 mm) diameter, flush
5/8 in (16 mm) diameter, 1/8 in (3.2 mm) exposed
#951 066
200(208)/230 V, 60 Hz with Spoolmatic® 30A, dual cylinder rack,
elevated gun and cable rack, regulator and hose
230/460/575 V, 60 Hz with Spoolmatic® 30A, dual cylinder rack,
elevated gun and cable rack, regulator and hose
.035 (0.9 mm)
.040 (1.0 mm)
.047 (1.2 mm)
5/8 in (16 mm) diameter
5/8 in (16 mm) diameter, HD
3/4 in (19 mm) diameter
3/4 in (19 mm) diameter, HD
Price
Aluminum Configuration (Spool Gun)
Millermatic® 252 Spool Gun Packages
(Also includes standard M-25 MIG gun)
#951 065
Spool Gun Contact Tips (10 per package)
Spool Gun Nozzles
#206 187
#206 188
#206 189
#198 855
#199 618
#199 616
#199 617
For M-25 gun consumables and Millermatic 252 drive rolls see steel configuration chart above.
Aluminum Configuration (Push-Pull Guns)
Millermatic® 252
(Includes standard M-25 MIG gun)
XR™-A Aluma-Pro Gun
XR™-A Pistol
XR™-A Pistol U-Groove Drive Roll Kits (required)
XR™-A Aluma-Pro U-Groove Drive Roll Kits
(required)
Contact Tips (10 per package)
Nozzles
Dual EZ-Change™ Low Cylinder Rack with
Elevated Gun and Cable Rack
Elevated Gun and Cable Rack
#907 321
#907 322
#300 000
#300 001
#198 127
#198 128
#195 201
#195 273
#195 202
#195 311
#195 312
#195 313
#206 187
#206 188
#206 189
#198 855
#199 618
#199 616
#199 617
#300 337
200(208)/230 V, 60 Hz
230/460/575 V, 60 Hz
15 ft (4.6 m)
25 ft (7.6 m)
15 ft (4.6 m)
30 ft (9.1 m)
.035 (0.9 mm)
.040 (1.0 mm)
.047 (1.2 mm)
.035 (0.9 mm)
.040 (1.0 mm)
.047 (1.2 mm)
.035 (0.9 mm)
.040 (1.0 mm)
.047 (1.2 mm)
5/8 in (16 mm) diameter
5/8 in (16 mm) diameter, HD
3/4 in (19 mm) diameter
3/4 in (19 mm) diameter, HD
#300 335
For use with single cylinder rack.
(Included with Dual EZ-Change Low Cylinder Rack.)
For M-25 gun consumables and Millermatic 252 drive rolls see steel configuration chart above.
Date:
Total Quoted Price:
7
Ordering Information
Accessories
Gun Convenience Kit for Steel
#193 975
(Order from Miller Service Parts.)
XR -A Aluma-Pro
#300 000
#300 001
15 ft (4.6 m)
25 ft (7.6 m)
XR™-A Pistol Gun
#198 127
#198 128
15 ft (4.6 m)
30 ft (9 m)
M-25 Gun
#169 594
#169 596
10 ft (3 m), .023 –.035 in (0.6 – 0.9 mm)
12 ft (3.7 m), .023 –.035 in (0.6 – 0.9 mm)
#169 598
15 ft (4.6 m), .023 –.035 in (0.6 – 0.9 mm)
Spoolmatic® 15A
#195 156
Spool gun for aluminum
Spoolmatic® 30A
#130 831
Spool gun for aluminum
Dual EZ-Change™ Low Cylinder Rack with
Elevated Gun and Cable Rack
#300 337
Elevated Gun and Cable Rack
#300 335
Protective Cover with Helmet Bag
#195 142
Features side pocket and helmet bag
Argon/Mixed Gas Regulator and Gas Hose
#195 050
(Order from Miller Service Parts.)
CO2 Regulator/Flow Gauge
#237 702
Required if using 100% CO2 gas. (Order from Miller Service Parts.)
™
™
For use with single cylinder rack.
(Included with Dual EZ-Change Low Cylinder Rack.)
Date:
Total Quoted Price:
Note: See page 7 for ordering information on Millermatic 252, available packages, and steel and aluminum configurations.
Distributed by:
Litho in USA
Deltaweld Series
Issued April 2008 • Index No. DC/16.2
®
Quick
Specs
MIG Welding
Power Source
Heavy Industrial Applications
Processes
Input Power
Heavy Equipment Manufacturing
Truck and Trailer Manufacturing
Ship and Boat Building
Tank/Pressure Vessel Fabrication
Manufacture of Automotive Equipment
Railcar/Locomotive Fabrication and Repair
Furniture Manufacture
Structural Steel Fabrication
Sheet Metal Fabrication
Maintenance
MIG (GMAW)
Flux Cored (FCAW)
Air Carbon Arc (CAC-A)
Cutting and Gouging
Submerged Arc (SAW)
302/402: 3-Phase Power
452/602: 3-Phase Power
652/852: 3-Phase Power
Rated Output
302/402: 300 A at 32 VDC, 100% Duty Cycle
452/602: 450 A at 38 VDC, 100% Duty Cycle
652/852: 650 A at 44 VDC, 100% Duty Cycle
Weight
302/402: 323 lb (147 kg)
452/602: 384 lb (174 kg)
652/852: 472 lb (214 kg)
The Power of Blue .
®
Superior arc welding performance
with MIG welding.
NEW! MIG Power Source Solutions
See option and package
descriptions on page 5.
Internal digital voltage control (DVC)
enables operator to preset weld
voltage before striking an arc.
Remote on/off capabilities allow
operator to turn power source
on/off from a distance.
Remote voltage control allows
operator to change voltage from
feeder.
Two positive output terminals provide
high/low stabilizer selection. Allows
operator to optimize arc performance.
Power efficient for exceptional value
and return on your investment.
Line voltage compensation ensures
consistent weld performance by
keeping output power constant even if
primary input power varies by ±10%.
Fan-On-Demand™ operates only
when needed reducing noise, power
consumption, and the amount of
airborne contaminants pulled
through the machine.
Simple control panel provides
easy, efficient operation.
Enclosed circuit boards provide
additional protection from
contaminants resulting in longer
service life.
Digital voltmeter and ammeter are
easy to read, even at 30 ft (9.2 m).
14-pin receptacle provides quick,
direct connection to Miller 14-pin wire
feeders and accessories.
PC board protection prevents the
wire feeder power or other stray
voltages (less than 115 VAC) from
harming the power source PC board.
115 V duplex receptacle provides
15 amps of auxiliary power.
Deltaweld® 452
MIGRunner®
Package shown
Thermal overload protection light
indicates power shutdown. Helps
prevent machine damage if the duty
cycle is exceeded or airflow is blocked.
Power cord strain relief provided
for your convenience at installation.
Power source is warranted for 3 years, parts and labor.
Original main power rectified parts are warranted for 5 years.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
®
Deltaweld 302/402 Specifications
Rated Output
300 A at 32 VDC,
100% Duty Cycle
Voltage
Range
Max. OpenRecommended Circuit
Welding Range Voltage
10–32 V
15 – 32 V
(Subject to change without notice.)
Amps Input at Rated Output, 50/60 Hz
200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW
44 VDC
48
42
27
25
23
21
17
16.9 12.9
Net
Weight
Dimensions
H: 30 in (762 mm)
including lift eye
W: 23 in (585 mm)
D: 30-1/2 in (775 mm)
including strain relief
Note: For input conductor and fuse size information consult the Owner’s Manual.
Certified to both the Canadian and U.S. Standards for welding equipment.
50 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1.
Control Panel
1
4
2
5
3
6
1. Voltage Adjustment Control
2. Output Switch
3. Remote Voltage Control Switch
4. Digital Meters
5. Power Switch with Indicator Light
6. High Temperature Shutdown Light
Performance Data
DUTY CYCLE CHART
VOLT/AMP CURVE CV
RATED OUTPUT
600
80
GMAW
FCAW
70
60
DC VOLTS
WELDING AMPS
500
400
300
50
40
MAX.
30
MED.
20
MIN.
10
200
40
50
60
70
% DUTY CYCLE
2
80
90 100
0
0
50
100
150
DC AMPS
200
250
300
323 lb
(147 kg)
®
Deltaweld 452/602 Specifications
Rated Output
450 A at 38 VDC,
100% Duty Cycle
Voltage
Range
Max. OpenRecommended Circuit
Welding Range Voltage
10 – 38 V
15 – 38 V
(Subject to change without notice.)
Amps Input at Rated Output, 50/60 Hz
200 V 230 V 380 V 400 V 440 V 460 V 575 V KVA KW
48 VDC
72
63
39
37
33
32
25
25.1 21.1
Net
Weight
Dimensions
H: 30 in (762 mm)
including lift eye
W: 23 in (585 mm)
D: 38 in (966 mm)
including strain relief
384 lb
(174 kg)
Note: For input conductor and fuse size information consult the Owner’s Manual.
Certified to both the Canadian and U.S. Standards for welding equipment.
50 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1.
Control Panel
1
4
2
5
3
6
1. Voltage Adjustment Control
2. Output Switch
3. Remote Voltage Control Switch
4. Digital Meters
5. Power Switch with Indicator Light
6. High Temperature Shutdown Light
Performance Data
DUTY CYCLE CHART
VOLT/AMP CURVE CV
RATED OUTPUT
800
80
GMAW
FCAW
70
60
DC VOLTS
WELDING AMPS
600
400
300
50
MAX.
40
MED.
30
20
MIN.
10
200
40
0
50
60
70
% DUTY CYCLE
80
90 100
0
100
200
300
400
500
DC AMPS
3
®
Deltaweld 652/852 Specifications
Rated Output
650 A at 44 VDC,
100% Duty Cycle
(Subject to change without notice.)
Voltage
Range
Recommended
Welding Range
Max. OpenCircuit
Voltage
Amps Input at Rated Output, 50/60 Hz
230 V 380 V 400 V 440 V 460 V 575 V KVA
KW
Dimensions
10–44 V
15 – 44 V
54 VDC
96
34.2
H: 30 in (762 mm)
including lift eye
W: 23 in (585 mm)
D: 38 in (966 mm)
including strain relief
58
54
50
48
38
38.2
Net
Weight
472 lb
(214 kg)
Note: For input conductor and fuse size information consult the Owner’s Manual.
Certified to both the Canadian and U.S. Standards for welding equipment.
50 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1.
Control Panel
1
4
2
5
3
6
1. Voltage Adjustment Control
2. Output Switch
3. Remote Voltage Control Switch
4. Digital Meters
5. Power Switch with Indicator Light
6. High Temperature Shutdown Light
Performance Data
DUTY CYCLE CHART
VOLT/AMP CURVE CV
RATED OUTPUT
1000
80
GMAW
FCAW
70
800
600
DC VOLTS
WELDING AMPS
60
50
MAX.
40
MED.
30
20
400
MIN.
10
300
40
0
50
60
70
% DUTY CYCLE
4
80
90
100
0
100
200
300
400
DC AMPS
500
600
700
Genuine Miller Options
Air Filter Kit #042 939 Field
Reusable air filter helps protect internal
components from dust and dirt, reducing
need for maintenance and providing
extended service life. Easily attaches and
detaches from front of the power source.
Ground Current Sensor #195 048 Field
Disables power source if weld current is
present on primary ground.
Packages
NEW! MIG Power Source Solutions
Option #1: Deltaweld Power Sources
®
Deltaweld® 652
#903 396 (230/460/575 V, 60 Hz)
Purchase components separately.
Deltaweld® 302
#903 376 (200-208/230/460 V, 60 Hz)
#903 392 (230/460/575 V, 60 Hz)
Deltaweld® 452
#903 377 (200-208/230/460 V, 60 Hz)
#903 394 (230/460/575 V, 60 Hz)
Option #2: Deltaweld Stationary Packages
®
Comes complete With:
Stationary display without running
gear/cylinder rack.
Deltaweld® power source
S-74D wire feeder
Bernard® Q-Gun™
Industrial MIG 4/0 Kit:
Smith® regulator/flowmeter with 10 ft
(3 m) gas hose, 10 ft (3 m) 4/0 feeder
weld cable with lugs, and 15 ft (4.6 m)
work cable with 600-amp C-clamp
®
Deltaweld 302
#951 084 (200-208/230/460 V, 60 Hz)
#951 127 (230/460/575 V, 60 Hz)
Deltaweld® 452
#951 085 (200-208/230/460 V, 60 Hz)
#951 128 (230/460/575 V, 60 Hz)
Deltaweld® 652
#907 086 (230/460/575 V, 60 Hz)
Option #3: Deltaweld MIGRunner Packages
®
®
MIGRunner system with factory-installed
running gear/cylinder rack.
®
Deltaweld 302
#951 107 (200-208/230/460 V, 60 Hz)
#951 129 (230/460/575 V, 60 Hz)
Deltaweld® 452
#951 108 (200-208/230/460 V, 60 Hz)
#951 130 (230/460/575 V, 60 Hz)
Deltaweld® 652
#951 109 (230/460/575 V, 60 Hz)
Comes complete With:
Deltaweld® power source
S-74D wire feeder
Bernard® Q-Gun™
Industrial MIG 4/0 Kit:
Smith® regulator/flowmeter with 10 ft
(3 m) gas hose, 10 ft (3 m) 4/0 feeder
weld cable with lugs, and 15 ft (4.6 m)
work cable with 600-amp C-clamp
Factory installed running gear/cylinder
rack
5
Genuine Miller Accessories
Water Coolant Systems
For more information, see Miller Coolant
Systems Lit. Index No. AY/7.2.
Coolmate V3
NEW! Industrial MIG 4/0 Kit #300 390
Consists of Smith® regulator/flowmeter
with 10 ft (3 m) gas hose, 10 ft (3 m)
4/0 feeder weld cable with lugs, and 15 ft
(4.6 m) work cable with 600-amp C-clamp.
Remote On/Off Control #042 869
Allows you to turn power source on or off
from a distance of 20 ft (6 m). This is
especially useful if your power source is
located up in a mezzanine.
Polarity Control #042 871
This dual-function control is designed for
use with dual wire feeders or any application
where electrical isolation and/or polarity
reversing of weld current is required. Both
functions can be used at the same time.
Process Control Selector #042 872
Allows you to easily change weld processes.
Also includes features of Polarity Control.
Extension Cables for 14-Pin Plugs to
14-Pin Sockets
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.8 m)
This extension cord makes a direct
connection between the power source and
the accessory control or wire feeder. No
messy splicing or adapting required.
6
Coolmate 3
Standard Running Gear #042 886
The large 10 in (254 mm) rear wheels and
5 in (127 mm) front casters on this running
gear provide excellent mobility on the shop
floor, making it easier to move the power
source around and over cables and cracks.
Very easy to install. Handles double as weld
cable holder.
Standard Cylinder Rack #042 887
Holds two cylinders. Only installs on
Standard Running Gear.
Coolmate 4
Coolmate™ 3
#043 007 115 VAC
#043 008 230 VAC
For use with water-cooled torches rated
up to 600 amps. Unique paddle-wheel
indicator, external filter and easy fill spout.
Coolmate™ V3 #043 009 115 VAC
For use with water-cooled torches rated up
to 500 amps. Vertical design conveniently
mounts to Miller cylinder rack in place of
one cylinder.
Coolmate™ 4 #042 288 115 VAC
For use with water-cooled torches rated up
to 600 amps. Tough molded polyethylene
case with carrying handle.
Coolant #043 810
Sold in cases of four 1-gallon recyclable
plastic bottles. Miller coolants contain a
base of ethylene glycol and deionized water
to protect against freezing to -37˚F (-38˚C)
or boiling to 227˚F (108˚C). Also contains
a compound that resists algae growth.
Wire Feeder Options
Bench-Style Feeders
S-22A
S-24A
S-74S
S-74D
S-74DX
Lit. Index No.
M/11.0
M/11.0
M/3.0
M/3.0
M/3.0
Bench-Style Dual Feeders
D-74S
D-74D
D-74DX
M/3.0
M/3.0
M/3.0
Boom-Style Feeders
SS-74S12
SS-74S16
SS-74D12
SS-74D16
SS-74DX12
SS-74DX16
M/13.11
M/13.11
M/13.11
M/13.11
M/13.11
M/13.11
Boom-Style Dual Feeders
DS-74S12
DS-74S16
DS-74D12
DS-74D16
DS-74DX12
DS-74DX16
M/13.11
M/13.11
M/13.11
M/13.11
M/13.11
M/13.11
Portable Feeders
Suitcase 8RC
Suitcase 12RC
M/6.5
M/6.5
Portable Voltage Sensing Feeders
SuitCase™ X-TREME™ 8VS
SuitCase™ X-TREME™ 12VS
M/6.41
M/6.41
Aluminum Push-Pull Feeders
XR Control
M/1.7
Guns available:
XR-Aluma-Pro A
XR-Aluma-Pro W
XR-A Python
M/1.71
M/1.71
M/1.71
Hard Automation
Control Detach Kit 70 Series
M/3.0
7
Ordering Information
Equipment and Options
Stock No.
Description
#903 376*
#903 392*
#951 084*
#951 127*
#951 107*
#951 129*
#907 285**
#903 377*
#903 394*
#951 085*
#951 128*
#951 108*
#951 130*
#907 286**
#903 396*
#951 086*
#951 109*
#907 287**
#042 939
#195 048
200-208/230/460 V, 60 Hz
230/460/575 V, 60 Hz
200-208/230/460 V, 60 Hz
230/460/575 V, 60 Hz
200-208/230/460 V, 60 Hz
230/460/575 V, 60 Hz
380/400/440 V, 50 Hz w/CE
200-208/230/460 V, 60 Hz
230/460/575 V, 60 Hz
200-208/230/460 V, 60 Hz
230/460/575 V, 60 Hz
200-208/230/460 V, 60 Hz
230/460/575 V, 60 Hz
380/400/440 V, 50 Hz w/CE
230/460/575 V, 60 Hz
230/460/575 V, 60 Hz
230/460/575 V, 60 Hz
380/400/440 V, 50 Hz w/CE
Field
Field
Qty.
Power Source
Deltaweld® 302 Power Source Only
Deltaweld® 302 Stationary Package
Deltaweld® 302 MIGRunner Package
Deltaweld® 402 Power Source Only
Deltaweld® 452 Power Source Only
Deltaweld® 452 Stationary Package
Deltaweld® 452 MIGRunner Package
Deltaweld® 602 Power Source Only
Deltaweld® 652 Power Source Only
Deltaweld® 652 Stationary Package
Deltaweld® 652 MIGRunner Package
Deltaweld® 852 Power Source Only
Air Filter Kit
Ground Current Sensor
Wire Feeders
70 Series
22A
24A
SuitCase™ 8RC
SuitCase™ 12RC
SuitCase™ X-TREME™ 8VS
SuitCase™ X-TREME™ 12VS
XR™-Control
Swingarc™ Boom Feeders
Extension Cables
Miscellaneous
Industrial MIG 4/0 Kit
Remote On/Off Control
Polarity Control
Process Control Selector
Standard Running Gear
Standard Cylinder Rack
Coolmate™ 3
Coolmate™ V3
Coolmate™ 4
Coolant
Primary Power Cable
Secondary Welding Cables
Work Cable and Clamp
#193 066
#195 112
#194 938
#194 940
#300 093
#195 500
#181 538
#122 973
#122 974
#122 975
#300 390
#042 869
#042 871
#042 872
#042 886
#042 887
#043 007
#043 008
#043 009
#042 288
#043 810
See Lit. Index No. M/3.0
See Lit. Index No. M/11.0
See Lit. Index No. M/11.0
See Lit. Index No. M/6.5
See Lit. Index No. M/6.5
See Lit. Index No. M/6.41
See Lit. Index No. M/6.41
See Lit. Index No. M/1.7
See Lit. Index No. M/13.11
25 ft (7.6 m)
50 ft (15.2 m)
75 ft (22.8 m)
Includes Smith regulator/flowmeter with 10 ft (3 m) gas hose, 10 ft (3 m) 4/0 feeder
weld cable with lugs, and 15 ft (4.6 m) work cable with 600-amp C-clamp
115 VAC
230 VAC
115 VAC
115 VAC
Date:
*
**
Total Quoted Price:
Certified to both the Canadian and U.S. Standards for welding equipment.
50 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1.
Conforms with NEMA EW 1 “Electric Arc Welding Power Source,” Class I (100).
Distributed by:
Litho in USA
Price
22A and 24A
Quick
Specs
Issued May 2007 • Index No. M/11.0
24 Volt Constant-Speed
Wire Feeder
Industrial Applications
Processes
Input Power
Heavy- or Light-Duty
Fabrication Shops
Trailer Manufacturers
Furniture Manufacturers
Automotive Products
Educational Institutions
MIG (GMAW)
Flux Cored (FCAW)
Gas- and Self-Shielded
Electrode Wire Diameter Capacity
For use with CV power sources
24 VAC, 7 A, 50/60 Hz
22A: .023 – 5/64 (0.6 – 2.0 mm)
24A: .023 – 3/32 (0.6 – 2.4 mm)
Wire Speed
Weight
75 –750 IPM (1.9 –19 m/min)
22A: 36 lb (15.4 kg) 24A: 40 lb (18 kg)
The Power of Blue .
®
16 gauge sheet metal
housing is robust in rough
service applications and
less prone to damage.
Wire feed speed range is 75 –750!
This offers a wider operating range
than the competition.
Trigger hold control allows
operator to make long
extended welds without
having to hold gun trigger.
Run-in standard on 24A
for better arc-starting
performance on a variety
of wires. Optional for 22A.
Gear-driven drive rolls offer
smooth, positive and accurate
wire feed with long, uninterrupted
service life. 24A has four drive
rolls for larger wire diameters.
On-board burnback and motor
ramp control offers unmatched
starting and stopping performance
on a variety of power sources.
This helps to ensure positive
arc starting performance.
Specifications
Remote voltage control is
standard on 24A. Parameter
adjustments can be made in
weld cell or at a remote location.
Optional for 22A.
Both include performance-matched Bernard® Q™-Gun,
.035/.045 in drive roll and Centerfire™ contact tips.
(Subject to change without notice.)
Model
Input Power
Electrode Wire Diameter Capacity
Wire Speed
Dimensions
Net Weight
22A
24 VAC, 7 A,
50/60 Hz
.023 – 5/64 in (0.6 – 2.0 mm)
75 –750 IPM (1.9 –19 m/min)
H: 11 in (279 mm)
W: 10-3/4 in (273 mm)
D: 23-1/2 in (597 mm)
36 lb (15.4 kg)
24A
.023 – 3/32 in (0.6 – 2.4 mm)
Certified to both the Canadian and U.S. Standards for welding equipment.
Wire feeder is warranted for 3 years, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
40 lb (18 kg)
Control Panel
3
4
3
4
5
5
6
6
1
1
2
2
7
8
1. Gun Connection
2. Trigger Receptacle
3. Voltage/Wire Speed Meter*
4. Meter Selection Switch*
5. Remote Voltage Control**
Drive Roll Kits
7
8
6. Wire Speed Control
7. Jog/Purge
8. Trigger Hold (On/Off)
Power On/Off (on rear panel)
*Optional
**Optional on 22A, standard on 24A
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include the necessary guides and feature an anti-wear sleeve for inlet guide.
“U” groove for
soft wire or
soft-shelled
cored wires
“V” groove
for hard wire
Wire Size
22A 2-Roll Kit
“U” cogged for
extremely soft
wire or softshelled cored
wires (i.e., hard
facing types)
“V” knurled
for hard-shelled
cored wires
24A 4-Roll Kit
22A 2-Roll Kit
24A 4-Roll Kit
22A 2-Roll Kit
24A 4-Roll Kit
22A 2-Roll Kit
24A 4-Roll Kit
.023/.025 in (0.6 mm)
#087 131
—
—
—
—
—
—
—
.030 in (0.8 mm)
#079 594
#046 780
—
—
—
—
—
—
.035 in (0.9 mm)
#079 595
#046 781
#044 749
#044 750
#079 606
#046 792
—
—
.040 in (1.0 mm)
#161 189
#161 190
—
—
—
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#046 782
#079 599*
#046 785
#079 607
#046 793
#083 318
#083 319
.052 in (1.3/1.4 mm)
#079 597
#046 783
#079 600
#046 786
#079 608
#046 794
#083 317
#083 320
1/16 in (1.6 mm)
#079 598
#046 784
#079 601
#046 787
#079 609
#046 795
#079 614
#046 800
.068/.072 in (1.8 mm)
—
—
—
—
#089 984
#089 985
—
—
5/64 in (2.0 mm)
—
—
#079 602
#046 788
#079 610
#046 796
#079 615
#046 801
3/32 in (2.4 mm)
—
—
—
#046 789**
—
#046 797**
*Accommodates .045 and .047 in (3/64 mm) wires.
**3/32 in inlet guide (#194 264) is required when using 3/32 in drive rolls.
Nylon Wire Guides for Feeding Aluminum Wire
Wire Size
.035–.047 in (1.2 mm)
1/16 in (1.6 mm)
2
Inlet Guide
#151 203
#151 205
Note: “U” groove drive rolls are
recommended when feeding
aluminum wire.
(Order from Miller Service Parts.)
—
#046 802**
Genuine Miller Options and Accessories
Digital Display V/WFS #186 498 Field
Dual-function, back-lit LCD digital meter
with selector switch. The digital meter
allows the wire feed speed to be preset in
inches per minute or meters per minute.
The voltage function, if used with a current
manufactured Miller electronically
controlled constant voltage power source,
allows the arc voltage to be preset and
monitored on the digital display. When
used with voltage control #194 211.
Wire Reel
Assembly
Feeder Cart #142 382
A low-profile, creeper cart which allows the
operator to easily move the feeder around
the work area. Shipped disassembled.
Voltage Control #194 211 Field
Standard on 24A. Installs in front panel of
the feeder to allow remote voltage control
of most Miller electrically controlled CV or
CC/CV power sources.
Carrying
Handle
Note: The field kit voltage control includes a 10 ft (3 m)
cord that replaces the standard cord supplied with
the feeder.
Run-In Control #193 391 Field
Standard on 24A. A separate wire feed
speed adjustment to control wire speed
prior to arc initiation. This control may be
beneficial to aid arc starting with certain
types of power sources.
Feeder
Cart
Carrying Handle #193 762
For lifting and moving feeder. (Cannot be
used with wire reel assembly #108 008.)
Hanging Bail
Preflow/Postflow and Spot Control
#186 496 Field
Installs inside feeder under an easy access
hinged cover. Provides up to 5 seconds of
spot weld time and has adjustable timers
(0.25 to 5 seconds) for controlling gas flow
prior to arc initiation and after completion
of weld.
Reel or
Spool Cover
Hanging Bail #058 435
Suspends feeder over the work area.
Reel Cover #195 412
For 60 lb (27.2 kg) coil.
Spool Cover #057 607
For 12 in (304 mm) spool.
Turntable Assembly
Wire Reel
Assembly
#108 008
For 60 lb (27.2 kg)
coil of wire.
(Cannot be used
with carrying
handle #193 762.)
Turntable Assembly #146 236
Allows rotation of feeder as operator
changes work positions. This reduces
strain and bending on gun cable.
Spool Adapter #047 141
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
PSA-2 Control #141 604
Required when using the
22A wire feeder with power
sources having only 115 VAC
available. The PSA-2 control
can be conveniently mounted
on the wire feeder or positioned
at the power source. The
control is equipped with a 14-pin receptacle
for direct connection of the wire feeder
control cord. A short cord with a 4-pin Amp
plug is hard wired to the control. A 10 ft
(3 m) interconnecting cord with a 4-pin
Amp for connection to the PSA-2 and
Hubbell connectors for older-style Miller
CV power sources is included. The PSA-2
control can also be used with competitive
power sources requiring a contact closure
for contactor control.
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
These extension cords can be added to the
standard 10 ft cord to extend feeder farther
from the power source.
2/0 MIG Welding Accessory Kit #173 856
25 ft (7.6 m). Includes gas hose, weld
cable and work cable with clamp.
Carrying Cart #056 301
A utility cart for the wire feeder and other
miscellaneous welding supplies.
Height: 34 in (863 mm) Lower tray height:
9 in (228 mm) Shipped disassembled.
3
Ordering Information
Power Source and Options
Stock No.
Description
22A
#193 066
#193 066-01-1
#193 066-02-2
With run-in control
With digital display and voltage control
24A
Drive Roll Kit
#195 112
Digital Display Meter
#186 498
Field.
Voltage Control
#194 211
Field. Standard on 24A
Run-In Control
#193 391
Field. Standard on 24A
Preflow/Postflow and Spot Control
#186 496
Field
Qty.
See table on page 2
Power Sources
CP-302
See Lit. Index No. DC/13.0
XMT 456
See Lit. Index No. DC/18.8
Deltaweld 302
See Lit. Index No. DC/16.2
XMT 350 CC/CV
See Lit. Index No. DC/18.8
XMT-304 CC/CV
See Lit. Index No. DC/18.8
Invision 354 MP
See Lit. Index No. DC/23
Accessories
Carrying Cart
#056 301
Feeder Cart
#142 382
Carrying Handle
#193 762
Hanging Bail
#058 435
Reel Cover
#195 412
For 60 lb coil
Spool Cover
#057 607
For 12 in spool
Wire Reel Assembly
#108 008
Turntable Assembly
#146 236
Spool Adapter
#047 141
PSA-2 Control
#141 604
Extension Cords
#122 973
#122 974
#122 975
For 14 lb spool of Lincoln self-shielding wire
25 ft
50 ft
75 ft
Bernard® Q™-Gun
Roughneck® MIG Guns
Miscellaneous
Primary Power Cable
Secondary Weld Cable
Work Cable with Work Clamp
Gas Cylinder
Gas Hose with Fittings
Regulator/Flowmeter
Welding Wire
Helmet
Welding Gloves
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price
SuitCase 8VS
Issued October 2006 • Index No. M/6.4
™
Quick
Specs
Voltage-Sensing
Wire Feeder
Industrial Applications
Processes
Input Power
Shipbuilding
Construction
Heavy Manufacturing
Rental
MIG (GMAW)
Flux Cored (FCAW)
Weight
The Power of Blue .
15 – 100 VDC
23.5 lb (10.7 kg)
®
Durable!
Ergonomically sound, lightweight unit
is well balanced, for ease of carrying to
remote welding sites. Fits through a
14 in (25 mm) manhole/manway
Quick-change drive rolls are easy
to change — no tools required.
Most durable case
in its class!
Drive roll accessibility makes it
easy to install wire, adjust tension
and change drive rolls.
Carrying handle folds down out
of way, yet is large enough for a
gloved hand.
Versatile feeder can run wire
diameters up to 1/16 in (1.6 mm).
Standard contactor and gas
solenoid control OCV and gas flow.
Simple control panel eliminates
operator confusion.
Totally enclosed, impact-resistant,
flame-retardant case provides
strength and durability, protecting
components and weld wire from
moisture, dust and contaminants.
Gas purge purges gas line without
feeding wire, or energizing weld
wire.
Overload protection protects motor
and control circuit against possible
damage due to overloading conditions.
Operates on open-circuit or arc
voltages, eliminating the need for
a control cable between the power
source and feeder.
Component assembly is easily
removed for servicing.
Specifications
Input Power
Open-Circuit
Arc Voltage
15 –100 VDC
SuitCase™ 8VS with
Q300 Bernard® Gun
shown (not included)
Universal feeder operates with
most Miller and competitive
CV/CC DC power sources.
(Use with CC/CV,
DC Power Sources.)
(Subject to change without notice.)
Welding Power
Source Type
Input Welding
Circuit Rating
Constant
Voltage (CV)
or Constant
Current (CC) DC
330 A at
60% Duty
Cycle
Electrode Wire Diameter Capacity
Maximum Spool
Size Capacity
Solid Wire: .023–1/16 in (0.6–1.6 mm)
Flux Cored: .030–1/16 in (0.8–1.6 mm)
8 in (203 mm)
14 lb (6.4 kg)
Net
Weight
Wire Speed
Dimensions
50–700 IPM
(1.3–18 m/min)
dependent on
arc voltage
H: 14-1/2 in (368 mm) 23.5 lb
W: 6-1/2 in (165 mm) (10.7 kg)
D: 15-5/8 in (397 mm)
Wire feeder is warranted for 3 years, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Control Panels
Drive Roll Kits
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits
include 2 drive rolls, the necessary guides and feature an anti-wear sleeve for inlet guide.
Front Control Panel
1
(Order from Miller Service Parts.)
2
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
“V” knurled
for hard-shelled
cored wires
“U” cogged for
extremely soft wire
or soft- shelled cored
wires (i.e., hard
facing types)
.023 / .025 in (0.6 mm)
#087 131
—
—
—
.030 in (0.8 mm)
#079 594
—
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
—
.040 in (1.0 mm)
#161 189
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599
#079 607
#083 318
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
#083 317
1/16 in (1.6 mm)
#079 598
#079 601
#079 609
#079 614
.068/.072 in (1.8 mm)
—
—
#089 984
—
5/64 in (2.0 mm)
—
#079 602
#079 610
#079 615
(PERCENT)
3
1.
2.
3.
4.
5.
6.
Purge Switch
Power Control Switch
Wire Speed Control
Jog Switch
HI/LO Range Switch
CC/CV Switch
Ordering Information
Power Source and Options
Stock No.
Description
SuitCase 8VS™
#194 890
#194 890-01-1
#194 890-01-2
#194 890-01-3
#194 890-02-1
#195 029
Standard model
With trigger hold
With CE and trigger hold
With meters
With meters and trigger hold
Meters (field)
Interior Control Panel
LO
CC
5
6
4
HI
CV
Meter Kit
Qty.
Guns
Ironmate™ 1260 (FCAW)
Roughneck® C-Series (GMAW)
See Lit. Index No. AY/16.0
See Lit. Index No. AY/17.0
Power Sources
XMT® Series
Dimension™
Gold Star®
Mark VI™
Big Blue® 400/500
Big Blue® Turbo
PipePro™ 304
Big Blue® Air Pak™
Bobcat™ Series
Trailblazer® Series
See Lit. Index No. DC/18.8
See Lit. Index No. DC/19.2
See Lit. Index No. DC/8.1
See Lit. Index No. DC/9.8
See Lit. Index No. ED/10.8
See Lit. Index No. ED/10.3
See Lit. Index No. ED/10.6
See Lit. Index No. ED/10.5
See Lit. Index No. DC/4.4
See Lit. Index No. DC/4.77
Consumables
Drive Rolls
Wire
Date:
Distributed by:
Litho in USA
Total Quoted Price:
Price
70 Series
Quick
Specs
Issued Feb. 2007 • Index No. M/3.0
Constant-Speed
Wire Feeder
Heavy Industrial Applications
Processes
Heavy Manufacturing
Metal Fabrication
Construction
Light Manufacturing
MIG (GMAW)
Flux Cored (FCAW)
(Gas- and Self-Shielded)
Input Power 24 VAC, 10 A, 50/60 Hz
Electrode Wire Diameter Capacity .023 –5/64 in (0.6– 2 mm)
Wire Speed 50 –780 IPM (1.3 –19.8 m/min)
Weight 58 lb (26 kg)
All the features of the 60 Series, plus enhanced flexibility and
additional features.
The Power of Blue .
®
Models:
S-74D
Model
74S: Standard, basic design
74D: Digital meters
74DX: Deluxe — digital, full-feature
Bernard® Q-Gun™ and
drive rolls included.
One set of each .035 in
(0.9 mm) and .045 in
(1.1/1.2 mm) “V” groove
drive rolls.
S-74DX
Model
Easy access on/off switch
Trigger receptacle oriented in a downward position to reduce potential damage.
Trigger hold reduces operator fatigue by allowing the operator to make long
welds without having to energize the trigger continuously.
Automatic run-in control significantly improves arc starting performance.
Posifeed™ Wire Drive Assembly Features
24 VDC high-torque, permanent-magnet motor.
Quick-change drive rolls.
Quick-release, calibrated drive-roll pressure adjustment arm allows
drive roll change without losing spring preload setting.
Four sealed ball bearing all-gear-driven drive-roll carriers for smooth,
positive and accurate wire feed with long uninterrupted service life.
Easy loading and threading of welding wire without having to release
the drive-roll pressure arm.
Solid-state speed control and brake circuit eliminates the need for
electrical/ mechanical relays and increases service life.
Uses Miller standard 1-5/8 in (41 mm) diameter drive rolls.
Quick-connect for all Miller guns.
Covered drive rolls — easy access, heavy-duty, molded composite
cover over drive assembly.
Floating positive drive systems provide trouble-free feeding on a
variety of wires.
10 ft, 14-pin
interconnecting cord
for the operator to
hook up.
DX Models Additional Features
Dual schedule allows operator to switch between two welding parameters
without readjusting machine, eliminating downtime and enhancing quality.
Adjustable weld sequence control gives operator complete control of the
welding parameters: preflow, run-in, weld time, crater, burnback and postflow.
Welding process range control locks parameters at a set percentage of
welding parameters to ensure welding procedures and quality standards
are maintained on the shop floor.
Four weld programs allow the operators to store four independent
welding parameters reducing welding setup time. (Four programs
available per side on dual model.)
Wire feeder is warranted for
3 years, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
Input Power
24 VAC, 10 A,
50/60 Hz
(Use with CV
Power Sources.)
(Subject to change without notice.)
Electrode Wire
Diameter Capacity
.023–5/64 in (0.6 – 2 mm)
Wire Speed*
Dimensions
S-74 (Single)
D-74 (Dual)
Net Weight
S-74 (Single) D-74 (Dual)
50–780 IPM (1.3–19.8 m/min)
Optional High Speed Motor:
90–1440 IPM (2.3–36.6 m/min)
H: 14 in (356 mm)
W: 12 in (305 mm)
D: 26-1/2 in (673 mm)
H: 14 in (356 mm)
W: 12-1/2 in (318 mm)
D: 35 in (889 mm)
58 lb (26 kg)
87 lb (35.5 kg)
*Note: When using 3/32 – 1/8 in (2.4 – 3.2 mm) wires contact Miller Electric Mfg. Co. at 1-920-735-4505 for more information on Low Speed options.
Control Panel
S-74DX Model
1. Program Display
2. Program # Select
3. Weld Sequence
4. Voltage/Time Select
5. Voltage/Time
Display Meter
6. Wire Feed/
Amperage Select
7. Wire Speed/
Amperage Display
Meter
8. Control Knob
9. Trigger Hold/Dual
Schedule Control
10. Jog/Purge
S-74S and S-74D Model
1
2
4
5
6
7
3
8
9
1. Voltage Display
Meter*
2. Wire Speed
Display Meter*
3. Wire Feed
Speed Select
4. Trigger Hold
5. Voltage Select**
6. Jog/Purge
1
2
3
5
*S-74D model only
**Optional on S-74S
4
70 Series
®
Drive Roll Kits and Guides
6
10
24V Wire Feeder
70 Series
24V Wire Feeder
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include 4 drive rolls, the necessary guides and feature an
anti-wear sleeve for inlet guide.
Wire Size
“U” groove for
soft wire or
soft-shelled
cored wires
“V” groove
for hard wire
.023/.025 in (0.6 mm)
.030 in (0.8 mm)
.035 in (0.9 mm)
.040 in (1.0 mm)
.045 in (1.1/1.2 mm)
.052 in (1.3/1.4 mm)
1/16 in (1.6 mm)
.068/.072 in (1.8 mm)
5/64 in (2.0 mm)
3/32 in (2.4 mm)
7/64 in (2.8 mm)
1/8 in (3.2 mm)
#151 024
#151 025
#151 026
#161 190
#151 027
#151 028
#151 029
—
—
—
—
—
*Accommodates .045 and .047 (3/64 in) wire.
“U” cogged
for extremely soft
wire or soft-shelled
cored wires (i.e.,
hard facing types)
“V” knurled for
hard-shelled
cored wires
—
—
#151 036
—
#151 037*
#151 038
#151 039
—
#151 040
#151 041
#151 042
#151 043**
—
—
#151 052
—
#151 053
#151 054
#151 055
#151 056
#151 057
#151 058
#151 059
#151 060**
—
—
—
—
#151 070
#151 071
#151 072
—
#151 073
#151 074
#151 075
#151 076**
** May require a low-speed, wire-feed drive-roll option.
Nylon Wire Guides for Feeding Aluminum Wire
Wire Guides
Wire Size
Inlet Guide
Intermediate Guide
Wire Size
Inlet Guide
Intermediate Guide
.047 in (1.2 mm)
#151 203
#151 204
.023 – .040 in (0.6 – 1.0 mm)
#150 993
#149 518
1/16 in (1.6 mm)
#151 205
#151 206
.045 – .052 in (1.1 – 1.4 mm)
#150 994
#149 519
3/32 in (2.4 mm)
#151 207
#151 208
1/16 – 5/64 in (1.6 – 2 mm)
#150 995
#149 520
3/32 – 7/64 in (2.4 – 2.8 mm)
#150 996
#149 521
1/8 in (3.2 mm)
#150 997
#149 522
Note: “U” groove drive rolls are recommended when feeding aluminum wire.
2
Genuine Miller Options and Accessories
Dual Schedule Switches
Remote Voltage Control
#194 988 Field Non-digital for S-74S
#194 991 Field Non-digital for D-74S
Conversion Kit
#194 989 Field
#194 992 Field
#195 010 Field
#195 041 Field
S-74S to S-74D
D-74S to D-74D
S-74S to S-74DX
D-74S to D-74DX
Control Detachment Kit
#194 914 Field 10 ft (3 m) for S-74
#194 913 Field 25 ft (7.6 m) for S-74
#194 995 Field 25 ft (7.6 m) for D-74
Allows separation of the control module
from the wire drive assembly and base.
Spool Covers
#057 607 For S-74 and left side of
D-74 models
#090 389 For right side of D-74 models
For 12 in (305 mm) spool.
Carrying Cart #056 301
A utility cart for the wire feeder and
other miscellaneous welding supplies.
Height: 34 in (863 mm). Lower tray height:
9 in (228 mm). Shipped disassembled.
DSS-9 #071 833
A two-position slide switch which attaches
to the gun handle and is used to select the
desired welding condition for dual schedule
purposes. The gun trigger operates as a standard gun trigger. (For 74DX models only.)
Feeder Cart #142 382
A low-profile, creeper cart which allows the
operator to easily move the feeder around
the work area. Shipped disassembled.
Turntable Assembly #146 236
Allows rotation of the feeder as the operator
changes work positions. Reduces strain
and bending on the gun cable.
Hanging Bail (Electrically Isolated)
#058 435
Used for suspending feeder over work area.
Wire Reel Assembly #108 008
For 60 lb (27 kg) coil of wire.
Reel Covers
#058 256 For S-74 and left side of
D-74 models
#091 668 For right side of D-74 models
For 60 lb (27 kg) coil. Helps to protect
the welding wire from dust and other
contaminants.
Note: Reel and Spool Covers cannot be installed if
the wire drive assembly is in a rotated position.
Spool Adapter #047 141
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
Wire Straightener
#141 580 For .035 –.045 in (0.9 –1.1 mm)
diameter wire.
#141 581 For 1/16 –1/8 in (1.6 – 3.2 mm)
diameter wire.
Helps reduce the cast in wire to improve
wire feeding performance and increase the
service life of the gun liner and contact tip.
DSS-8 #079 693
A two-position trigger switch which
attaches to the gun handle and is used in
place of the standard trigger for dual
scheduling. (For 74DX models only.)
2/0 MIG Welding Accessory Kit #173 856
25 ft (7.6 m). Includes gas hose, weld
cable and ground cable with clamp.
Swingarc™ Boom-Mounted Wire Feeders
Swingarc boom-mounted semiautomatic
wire feeders bring an extra dimension of
flexibility and efficiency to high-production
wire welding stations. You get an effective
solution that maximizes output, especially
when dealing with large weldments and
hard-to-reach places. See Lit. Index No.
M/13.11.
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
Provides 14-pin, 24 VAC, contactor and
voltage control. Add to the standard 10 ft
(3 m) feeder cord to extend feeder farther
from power source.
3
Typical Installation
10 ft (3 m) 24 VAC, Contactor and
Voltage Control Cord (supplied with feeder)
Miller electrically controlled
CV and CC/CV power source
with a 14-pin receptacle and
24 VAC supply
Weld Power Cable and Gas Hose
(not supplied with feeder)
70 Series Feeder
Ordering Information
Equipment and Options
Stock No.
Description
S-74S
#195 057
#195 057-02-1
#195 058
#195 058-01-1
#195 058-02-1
#195 058-03-1
#195 059
#195 059-01-1
#195 059-02-1
#195 059-03-1
#195 060
#195 060-02-1
#195 061
#195 061-01-1
#195 061-02-1
#195 061-03-1
#195 062
#195 062-01-1
#195 062-02-1
#195 062-03-1
#194 988
#194 991
#194 989
#194 992
#195 010
#195 041
#194 914
#194 913
#194 995
15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
15 ft (4.6 m) Bernard Q400 gun and drive rolls
With high-speed motor, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, high-speed motor, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
15 ft (4.6 m) Bernard Q400 gun and drive rolls
With high-speed motor, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, high-speed motor, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
15 ft (4.6 m) Bernard Q400 gun and drive rolls
With high-speed motor, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, high-speed motor, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
15 ft (4.6 m) Bernard Q400 gun and drive rolls
With high-speed motor, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
With CE, Euro, high-speed motor, 15 ft (4.6 m) Bernard Q400 gun and drive rolls
Field. Non-digital control (S-74S model only)
Field. Non-digital control (D-74S model only)
Field. S-74S to S-74D
Field. D-74S to D-74D
Field. S-74S to S-74DX
Field. D-74S to D-74DX
Field. 10 ft (3 m) (S-74S model only)
Field. 25 ft (7.6 m) (S-74S model only)
Field. 25 ft (7.6 m) (D-74S model only)
#Q4015AE8EM
400 A, 15 ft (4.6 m)
S-74D
S-74DX
D-74S
D-74D
D-74DX
Remote Voltage Control
Conversion Kit
Control Detachment Kit
Replacement Gun and Consumables
Bernard® Q400
Centerfire™ consumables
Power Sources
CP-302
Invision™ 354 MP and 456MP, 456P
Deltaweld® Series
XMT® Series
Dimension™ Series
Accessories
Adapter Kit
Carrying Cart
Feeder Cart
Turntable Assembly
Hanging Bail
Wire Straightener
Spool Covers
Wire Reel Assembly
Reel Covers
Spool Adapter
2/0 MIG Welding Accessory Kit
Extension Cords
Dual Schedule Switches
See Lit. Index No. DC/13.0
See Lit. Index No. DC/23, DC/20
See Lit. Index No. DC/16.2
See Lit. Index No. DC/18.8
See Lit. Index No. DC/19.2
#195 043
#056 301
#142 382
#146 236
#058 435
#057 607
#090 389
#108 008
#058 256
#091 668
#047 141
#173 856
#079 693
#071 833
Makes 70 Series feeder compatible with older-style power sources
Electrically isolated
See page 3
For S-74 and left side of D-74 models
For right side of D-74 models
For S-74 and left side of D-74 models
For right side of D-74 models
See page 3
DSS-8 (74DX models only)
DSS-9 (74DX models only)
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Qty.
Price
Spool Guns and Controls
January 2005 • Index No. M/1.5
Wire
Feeder
Spoolmate 3035, Spoolmate 3545, and Spoolmatic 15A/30A
™
Quick
Specs
™
Light and Heavy
Industrial Applications
®
Processes
Weight
MIG (GMAW)
with aluminum
and other wires
Aluminum Fabrication
Sign Manufacturing
Trailer Fabrication
Auto and Marine Repair
Spoolmate 3035: 9 lb (4.1 kg) with cable assembly
Spoolmate 3545: 10 lb (4.5 kg) with cable assembly
Spoolmate 15A: 9 lb (4.1 kg) with cable assembly
Spoolmatic 30A: 14 lb (6.4 kg) with cable assembly
The Power of Blue .
®
Spoolmate™ 3035
Improved!
Spoolmatic®
15A /30A
Barrel and Handle
These reliable yet economical Spoolmate spool guns provide 20 ft
cable reach and accessibility, with smooth feeding of aluminum wire.
Industrial, well-balanced Spoolmatic 15A/30A spool gun features a
built-in gas valve, rotatable canister, all-wire dual groove drive roll and
15 ft (15A) or 30 ft (30A) cable reach. New barrels are Roughneck and
Bernard Centerfire compatible. (See page 4 for optional consumables.)
Selecting a Spool Gun
What wire sizes
are you running?
Spoolmate™ 3545
What welding output?
Recommended gun
.023 – .035 in
150 A at 60% duty cycle —
light industrial applications
Spoolmate 3035
.030 – .047 in
200 A at 60% duty cycle —
light industrial applications
Spoolmate 3545
.030 – 1/16 in
200 A at 100% duty cycle —
light and heavy industrial
applications
Spoolmatic 15A/30A
Spoolmate guns warranted for 90 days,
parts and labor. Spoolmatic guns
warranted for 1 year, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
(Spoolmate — use with CV, DC Power Sources.)
(Spoolmatic — use with CC/CV, DC Power Sources.)
(Subject to change without notice.)
Spool Gun Specifications
Wire Speed
Maximum Spool
Size Capacity
.023 –.035 in (0.6 – 0.9 mm)
aluminum, steel and stainless steel
115–715 IPM
4 in (102 mm)
200 A at
60% Duty Cycle
.030–.047 in (0.8–1.2 mm) aluminum,
steel and stainless steel
200–1200 IPM
200 A at
100% Duty Cycle
.030–1/16 in (0.6–1.6 mm) aluminum
and hard wires up to .045 in (1.1 mm)
70–875 IPM
Model
Welding
Output Rating
Electrode Wire
Diameter Capacity
Spoolmate
3035
150 A at
60% Duty Cycle
Spoolmate
3545
Spoolmatic
15A
Spoolmatic
30A
Dimensions
Net Weight with
Cable Assembly
H: 11-1/2 in (291 mm)
W: 2-1/4 in (57 mm)
L: 8 in (203 mm)
9 lb (4.1 kg)
H: 10-1/4 in (260 mm)
W: 2-1/2 in (64 mm)
L: 15-1/8 in (384 mm)
9 lb (4.1 kg)
10 lb (4.5 kg)
14 lb (6.4 kg)
Spool Gun Control Specifications
Usage
Model
Input Power
Dimensions
Net Weight
For Spoolmate
3035 and 3545
SGA 100
115 VAC, 50/60 Hz
H: 4-1/4 in (108 mm) W: 6-3/8 in (162 mm) L: 10-1/2 in (267 mm)
9 lb (4.1 kg)
SGA 100C
115 VAC, 50/60 Hz
H: 8-1/4 in (210 mm) W: 6-3/8 in (162 mm) L: 10-1/2 in (267 mm)
12 lb (5.4 kg)
For Spoolmatic
15A/30A
WC-24
24 VAC, 50/60 Hz
H: 7 in (178 mm) W: 5-1/2 in (140 mm) L: 2 in (51 mm)
2 lb (0.9 kg)
WC-115A
115 VAC, 50/60 or 100 Hz
H: 10 in (254 mm) W: 9-1/2 in (241 mm) L: 13 in (330 mm)
20 lb (9 kg)
Spool Gun Hook-Up Recommendations
Power Source
Effective
Serial Number
Spoolmate 3035 #195 016
150 A, 60% Duty Cycle
Spoolmate 3545 #195 015
200 A, 60% Duty Cycle
Spoolmatic 15A #195 156/
Spoolmatic 30A #130 831
200 A, 100% Duty Cycle
Millermatic® 130 XP, 135
All
Limited to 14 gauge–1/8 in material
SGA 100 required #043 856
Not recommended
Not recommended
Millermatic®
Challenger 172, 175
All
SGA 100 required #043 856
Not recommended
Not recommended
Millermatic® 185
Prior to #KH376829
Retrofit Kit required #186 871 and #207 642
Retrofit Kit required #186 871
Not recommended
After #KH376829
Direct hook-up using toggle
switch field kit #207 642
Direct hook-up using toggle
switch field kit #207 642
Not recommended
Millermatic® 210
All
Direct hook-up, Gun-On-Demand™
Not recommended
Not recommended
®
Millermatic Vintage, 250
All
Not recommended
SGA 100 required #043 856
Module required #043 084
Millermatic® 250X, 251
All
Not recommended
Not recommended
Direct hook-up
®
All
Not recommended
Not recommended
Direct hook-up, Gun-On-Demand™
Millermatic 350, 350P
2
Spoolmate 3035 and 3545 Spool Gun Controls
SGA 100 #043 856
Required to connect Spoolmate spool gun
to the Millermatic 135 or 175. Allows you to
connect a Spoolmate gun to virtually any
similar MIG welder — Miller or other brands.
Includes 10 ft (3 m) 115 VAC power cable
and plug, 6 ft (1.8 m) interconnecting cable,
and 5 ft (1.5 m) gas hose.
Note: For CV engine drives like Miller Bobcat ™,
use the SGA 100C with contactor (#043 857).
SGA 100C #043 857
SGA with contactor required to connect
Spoolmate spool gun to CV engine drives
like Miller’s Bobcat ™.
Includes 10 ft (3 m) 115 VAC power cable
and plug, 6 ft (1.8 m) interconnecting cable,
and 5 ft (1.5 m) gas hose.
Genuine Miller Spoolmate Consumables and Accessories (Order Consumables from Miller Service Parts.)
Note: Spoolmate 3035 Gun shipped with 3–.030 in
and 3 – .035 in contact tips. Spoolmate 3545 Gun
shipped with 3–.035 in and 3 – .047 in contact tips.
Consumables For Spoolmate 3545
Accessories
25 ft Extension Cable #194 996
Consumables For Spoolmate 3035
Contact Tips (5 per package)
#199 730 For .023 in (0.6 mm) wire.
#186 419 For .030 in (0.8 mm) wire.
#186 406 For .035 in (0.9 mm) wire.
Nozzle #186 405
Drive Roll (1)
#199 731 For .023 in
(0.6 mm) wire.
#186 413 For .030/.035 in
(0.8/0.9 mm) wire.
Push Roll (1)
#199 732 For .023 in
(0.6 mm) wire.
#186 414 For .030/.035 in
(0.8/0.9 mm) wire.
Contact Tips (5 per package)
#199 387 For .030 in (0.8 mm) wire.
#199 388 For .035 in (0.9 mm) wire.
#199 389 For .047 in (1.2 mm) wire.
Spoolmate 3035 Heavy-Duty Barrel
#195 375
Ideal for demanding applications.
Rated at 200 A, 60% duty cycle.
Nozzle #199 386
Drive Roll (1)
#186 413 For .030/.035 in
(0.8/0.9 mm) wire.
#199 396 For .047 in
(1.2 mm) wire.
Push Roll (1)
#186 414 For .030/.035 in
(0.8/0.9 mm) wire.
#199 397 For .047 in
(1.2 mm) wire.
3
Spoolmatic 30A Spool Gun Controls
Standard features include a wire run-in
control and a drive motor acceleration
control which ensure optimum arc starting
performance, regardless of the type of
power source being used. The WC-115A
comes with a 10 ft (3 m), wall-type plug
power cord.
WC-24 Weld Control #137 549
Packaged in a compact, lightweight, nonmetallic enclosure, the WC-24 easily mounts
directly on the power source. It’s designed
for use with Miller CV power sources
supplying 24 VAC and 14-pin receptacles.
The control includes a board-mounted
potentiometer which can alter the drive
motor acceleration rate to optimize arc
starting performance.
WC-115A Weld Control
#137 546 Without contactor
#137 546-01-1 With contactor
This control operates on 115 VAC, and is
designed primarily for CC DC power sources.
It can also be used with CV power sources
or DC engine drives supplying 115 VAC.
When used with a CC source, the control
circuit functions in a voltage-sensing mode.
When used with a CV source, it functions
as a constant-speed circuit.
WC-115 Contactor Kit #137 548 Field
Recommended when using the Spoolmatic
gun and WC-115A control with power
sources that do not have a weld output
contactor. (This is installed in the WC-115A.)
Contactor Rating:
400 amps at 30% duty cycle
330 amps at 60% duty cycle
250 amps at 100% duty cycle
Genuine Miller Spoolmatic 30A Accessories
Hose and Cable Extension Kits
#132 228 25 ft (7.6 m)
#132 229 50 ft (15 m)
Extends Spoolmatic 30A away from the
control box. Convenient plug-in connections.
Includes gas hose, control cord, and weld
power cable with International-style
insulated connector.
Cable Cover #118 678
Protects gun hose and cable assembly
from wear and abrasion. Features a fulllength zipper.
Spare Spool Canister #132 230
Canister accommodates 4 in (102 mm)
spools of wire. Can be loaded with other
popular wires to save time in changeover.
Genuine Miller Spoolmatic 30A Consumables
(Order from Miller Service Parts.)
Wire Size
FasTip Contact Tip
Spoolmatic Drive Rolls
Spoolmatic All-Wire Dual Groove Drive Rolls
.030 in (0.8 mm)
.041 in ID #206 186
#183 357
#136 135
.035 in (0.9 mm)
.047 in ID #206 187
#183 357
#136 135
.040 in (1.0 mm)
.053 in ID #206 188
#183 357
#136 135
.047 in (1.2 mm)
.061 in ID #206 189
#183 358
#136 135
.062 in (1.6 mm)
.071 in ID #206 190
#183 358
#136 135
Each gun is shipped with .035 in and .047 in standard tips.
Assembly #221 295
1
4
2
3
4
5
6
7
8
9
1.
2.
4.
5.
5.
6.
7.
8.
9.
Head Tube Liner
#212 156
O-Ring .614 ID
#134 800
Head Tube (Air-cooled)
#219 796
Barrel Pistol Insulator
#219 795
Outer Insulating Jacket
#219 794
Nozzle Insulator
#198 856
Diffuser
#206 195
Contact Tip
(See consumables)
Nozzle
(See optional consumables)
XR Gun Genuine Miller Accessories
XR-Pistol Gun Barrels (Air-Cooled)
10 in Head Tube-A #222 461
Ideal when a longer reach is required.
50 Degree Curved Barrel-A #222 462
6 in (152 mm). Used with .030–1/16 in
(0.8–1.6 mm) wire. Kits supplied with liner
that accommodates all wire sizes.
Replacement Liners for Air-Cooled Barrels
(Order from Miller Service Parts.)
For 6 in Curved Barrel
#212 411 .030–1/16 in (0.8–1.6 mm) wire
For 10 in Head Tube
#212 401 .030–1/16 in (0.8–1.6 mm) wire
10 in Flex Head-A #222 735
10 in (254 mm). For .030–1/16 in (0.8–1/6 mm)
wire. Used in place of the standard straight
barrel. Flexible head tube bends 60 degrees
in any direction for easier joint access and
improved operator comfort. Supplied with
liners. Uses FasTip™ contact tips.
For Flex Head
#222 853 .030–.035 in (0.8–0.9 mm) wire
#222 854 .047–.062 in (1.2–1.6 mm) wire
50 Degree Curved Nozzle Kit-A #147 174
Attaches to old-style gun barrel assembly
for access to confined weld joint areas.
Used with .030–1.16 in (0.8–1.6 mm)
wire. Kit includes two of each size contact
tips to accommodate all wire sizes, Nozzle
Adapter Kit (#193 794) and curved nozzle.
Uses standard straight barrel head tube liner.
Note: Kit only works with old-style colleted
multi-piece barrel #193 142 and can be ordered
through Miller Service Parts. Kit will not work
with new Roughneck-style one piece front end.
Replacement Contact Tips for Curved Nozzle
(Order from Miller Service Parts.)
#148 155 .030 and .035 in
(0.8 and 0.9 mm) wire
#148 154 .047 (1.2 mm) wire
#148 156 1/16 in (1.6 mm) wire
XR-Pistol Gun Barrels (Water-Cooled)
Replacement Liners for Air-Cooled Barrels
(Order from Miller Service Parts.)
For 6 in Curved Barrel
#212 411 .030–1/16 in (0.8–1.6 mm) wire
50 Degree Curved Barrel-W #222 464
6 in (152 mm). Used with .030–1/16 in
(0.8–1.6 mm) wire. Kits supplied with liner
that accommodates all wire sizes.
For 10 in Straight Barrel
#212 401 .030–1/16 in (0.8–1.6 mm) wire
10 in Straight Barrel-W #222 463
Used with .030–1/16 in (0.8–1.6 mm) wire.
Kits supplied with liner that accommodates
all wire sizes.
5
Genuine Miller Spoolmatic 30A Optional Consumables
Nozzles
FasTip™ Contact Tips
#176 238*
#176 240*
#176 242*
#199 610
#199 611
Heavy-Duty
#206 186 .030/.035 in (0.8/0.9 mm)
aluminum wire
#206 187 .040/.035 in (0.9/1.0 mm)
aluminum wire
#206 188 .040/.045 in (1.0/1.2 mm)
aluminum wire
#206 189 .052 in (1.3 mm) or
3/64 in (1.2 mm) aluminum wire
#206 190 1/16 in (1.6 mm)
#206 191 .068 in (1.7 mm) or
1/16 in (1.6 m) aluminum wire
Spot Flat
Spot Inside Corner
Spot Outside Corner
Screw-on brass, 1/2 in orifice
Screw-on brass, 3/4 in orifice
straight
#199 612 Screw-on brass, 3/4 in orifice
straight heavy-duty
#199 613 Screw-on brass, 5/8 in orifice
#199 614 Screw-on brass, 5/8 in orifice
heavy-duty
#199 615 Screw-on copper, 1/2 in orifice
#199 616 Screw-on copper, 3/4 in orifice
#199 617 Screw-on copper, 3/4 in orifice
heavy-duty
#198 855 Screw-on copper, 5/8 in orifice
#199 618 Screw-on copper, 5/8 in orifice
heavy-duty
#207 313 Screw-on copper, 5/8 in orifice
15/16 O.D.
#209 035** Screw-on copper, 3/8 in orifice
tapered
#209 036** Screw-on copper, 1/2 in orifice
tapered
(25 per package)
(Order from Miller Service Parts.)
Gas Diffusers
#206 195 Standard
1/8 in tip recess for heavy-duty FasTip
contact tips.
#210 664
1/4 in tip recess for heavy-duty FasTip
contact tips.
#206 196
Flush tip for heavy-duty FasTip contact tips.
Tapered
#209 026 .030/.035 in (0.8/0.9 mm)
aluminum wire
#209 027 .035/.045 in (0.9/1.2 mm)
aluminum wire
#209 028 3/64 in (1.2 mm)
#209 029 .052 in (1.3 mm)
#209 030 1/16 in (1.6 mm)
*Requires Diffuser #209 099, used with any heavyduty FasTip™ contact tip.
**Requires Diffuser #206 195, #206 196, or #210 664.
Used with any tapered FasTip™ contact tip.
Centerfire Series Consumables
®
T Series Contact Tips 1.5 in (38.1 mm)
T-030 .030 in (0.8 mm)
T-035 .035 in (0.9 mm)
T-039 .039 in (1.0 mm)
T-045 .045 in (1.2 mm)
T-052 .052 in (1.4 mm)
T-062 1/16 in (1.6 mm)
T-078 5/64 in (2.0 mm)
T-094 3/32 in (2.4 mm)
T-109 7/64 in (2.8 mm)
T-125 1/8 in (3.2 mm)
6
TT Series Contact Tips 2 in (50.8 mm)
TT-030 .030 in (0.8 mm)
TT-035 .035 in (0.9 mm)
TT-045 .045 in (1.2 mm)
TT-052 .052 in (1.4 mm)
TT-062 1/16 in (1.6 mm)
Insulator 10012
4323R
Diffuser
D-1
DS-1
Nozzles
N-3414C
N-3418B
N-3414B
N-5814C
N-5818B
N-5814B
Copper, 3/4 in I.D., 1/4 in tip recess
Brass, 3/4 in I.D., 1/8 in tip recess
Brass, 3/4 in I.D., 1/4 in tip recess
Copper, 5/8 in I.D., 1/4 in tip recess
Brass, 5/8 in I.D., 1/8 in tip recess
Brass, 5/8 in I.D., 1/4 in tip recess
NS-5818B Brass, 5/8 in I.D., 1/8 in tip recess
NS-1218B Brass, 1/2 in I.D., 1/8 in tip recess
NS-1200B Brass, 1/2 in I.D., flush tip
NST-3818B Brass, 3/8 in I.D., 1/8 in tip recess
Typical Installations
Spoolmate Gun to Welder Requiring a SGA Spool Gun Adapter
Note: Refer to SGA Owner’s Manual for complete installation instructions.
For Millermatic 135, combine Spoolmate 3035 with
SGA 100 to weld 14 gauge to 1/8 in aluminum.
Gas Hose to Gas Regulator
115 VAC Power Cord
For Millermatic 175, combine Spoolmate 3035 with
SGA 100 to weld 14 gauge to 1/4 in aluminum.
To weld aluminum with comparable, competitive
power sources, the Spoolmate may also be used with
one of the SGA units.
The SGA 100C is necessary when connecting
Spoolmate spool guns to CV engine drive units.
Thickness will depend on engine drive.
For Miller’s Bobcat 225NT, combine Spoolmate 3545
with SGA 100C to weld 14 gauge to 3/16 in aluminum.
To weld aluminum with comparable, competitive
power sources, the Spoolmate may also be used with
one of the SGA units.
Spool Gun Trigger
Control Cord
SGA-100
Control Box
Typical MIG welder such as the
Millermatic 135
Typical CV engine drive, without
output contactor, such as the
Miller Bobcat
Spoolmate Gun
Spool Gun Gas Hose
Interconnecting Cord
Spool Gun Weld Cable
Weld Cable (customer supplied)
SGA-100C
(with contactor)
OR
115 VAC Power Cord
Spool Gun
Weld Cable
Spoolmate Gun
Spool Gun Trigger
Control Cord
Spool Gun
Gas Hose
Gas Hose to Gas Regulator
Spoolmatic 15A/30A
Note: Cords and cables are supplied unless noted otherwise on drawings below. Refer to Owner’s Manual for complete installation instructions.
To connect the Spoolmatic 15A/30A and WC-24
control to older-style Miller or competitive CV power
sources that do not have a 24 VAC supply, the PSA-2
control #141 604 is required.
To connect Spoolmatic 15A/30A gun and WC-24
control to Millermatic® 200 and Spoolmate™ 200
power sources that have a 4-pin receptacle, order
adapter cord #042 236.
To connect the WC-115A control to older-style Miller
power sources having Hubbell or 5-pin contactor
control receptacles, the appropriate connector must
be ordered separately:
To connect to older-style Miller CC power sources having
a two-socket Hubbell connector, order plug #039 618.
If power source has a Miller 5-pin receptacle, order
#039 273 and #039 685.
To connect to older-style Miller CV power sources having
a two-prong Hubbell connector, order plug #039 635.
Miller CV, DC
power source
with a 14-pin
receptacle and
24 VAC supply
WC-24
Control
10 ft (3 m)
Control Cord
Control Cord
Weld Power
Cable
Spoolmatic Gun
40 ft (12 m) Gas Hose
Gas Hose
WC-115A
Control
Control Cord
Weld Power Cable
Miller and competitive CC and/or CV,
DC power source/generator. If the
power source does not have a weld
output contactor, order the optional
WC-115 contactor.
Spoolmatic Gun
Weld Power Cable (not included)
10 ft (3 m) Contactor Cord (supplied on non-contactor unit)
10 ft (3 m) 115 VAC Power Cord (supplied)
Note: These connectors are to replace the 14-pin connector
on the 10 ft interconnect contactor cord. Internal wiring
changes may be necessary.
7
Ordering Information
Equipment
Stock No.
Description
Spoolmate 3035 Spool Gun
#195 016
Includes 20 ft (6 m) cable
Spoolmate™ 3545 Spool Gun
#195 015
Includes 20 ft (6 m) cable
Spoolmatic® 15A Spool Gun
#195 156
Includes 15 ft (4.6 m) cable
Spoolmatic® 30A Spool Gun
#130 831
Includes 30 ft (9 m) cable
™
Qty.
Spoolmate Controls
SGA 100
#043 856
For Spoolmate guns
SGA 100C
#043 857
For Spoolmate guns
25 ft Extension Cable
#194 996
Control cable extension for Spoolmate 3035 and 3545
Spoolmate 3035 Heavy-Duty Barrel
#195 375
Rated at 200 A, 60% duty cycle
WC-24 Weld Control
#137 549
For Spoolmatic guns
WC-115A Weld Control
#137 546
#137 546-01-1
Without contactor. For Spoolmatic guns
With contactor. For Spoolmatic guns
WC-115 Contactor Kit
#137 548
Field
Spoolmate Consumables and Accessories
Consumables
See page 3
Spoolmatic 15A/30A Controls
Spoolmatic 15A/30A Consumables and Accessories
Consumables
See pages 4–6
Cable Cover
#118 678
Spare Spool Canister
#132 230
Hose and Cable Extension Kits
#132 228
#132 229
XR-Pistol Gun Barrels
Date:
Total Quoted Price:
Distributed by:
Litho in USA
25 ft (7.6 m)
50 ft (15 m)
See page 5
Price
S-74 MPa Single Feeder Features
Posifeed™ Wire Drive Assembly Features
(Synergic Pulsed MIG when connected to the Invision 350 MPa)
24 VDC high-torque, permanent-magnet motor.
Quick-change drive rolls.
Quick-release, calibrated drive-roll pressure adjustment arm allows drive roll change
without losing spring preload setting.
Four sealed ball bearing all-gear-driven drive-roll carriers for smooth, positive and
accurate wire feed with long uninterrupted service life.
Easy loading and threading of welding wire without having to release the drive-roll
pressure arm.
Solid-state speed control and brake circuit eliminates the need for electrical/
mechanical relays and increases service life.
Uses Miller standard 1-5/8 in (41 mm) diameter drive rolls.
Quick-connect for all Miller guns.
Covered drive rolls — easy access, heavy-duty, molded composite cover over
drive assembly.
Floating positive drive systems provide trouble-free feeding on a variety of wires.
Tool-less rotatable drive assembly
allows operator to rotate the drive
housing, eliminating severe bends in the
wire feed path which reduce gun liner
life. Also aids in feeding difficult wires.
Specifications
Dual tension control adds flexibility
for the operator to fine-tune the
pressure on the wire independently
when feeding a variety of wires.
(Use with CV
Power Sources.)
(Subject to change without notice.)
Input Power
Electrode Wire Diameter Capacity
Wire Speed
Dimensions
Net Weight
24 VAC, 10 A, 50/60 Hz
.023–5/64 in (0.6–2 mm)
50–780 IPM (1.3–19.8 m/min)
Optional High Speed Motor:
90–1440 IPM (2.3–36.6 m/min)
H: 14 in (356 mm)
W: 12 in (305 mm)
D: 26-1/2 in (673 mm)
58 lb (26 kg)
Control Panel
1
2
3
5
4
6
S-74 MPa
24V Wire Feeder
4
1. Voltage Display Meter
2. Wire Speed Display Meter
3. Wire Feed Speed Select
4. Trigger Hold
5. Voltage Select
6. Jog/Purge
SuitCase X-TREME 8VS & 12VS
™
Issued Sept. 2007 • Index No. M/6.41
™
Quick
Specs
Input Power
Industrial Applications
Processes
Shipbuilding
Construction
Heavy Manufacturing
Rental
MIG (GMAW)
Flux Cored (FCAW)
Voltage-Sensing
Wire Feeder
14 – 48 VDC Operating Voltage
110 VDC Maximum OCV
Wire Feed Speed 50 – 780 IPM (1.3 – 19.8 m/min)
Weight 8VS: 28 lb (13 kg)
12VS: 35 lb (15.9 kg)
The Power of Blue .
®
Now available in 8VS size
with many of the features of
the SuitCase X-TREME 12VS!
NEW! X-TREME 8VS — Now in smaller
8VS size for shipbuilding, maintenance or
wherever a lighter, smaller, more portable
feeder is required. Same great features
of its big brother the X-TREME 12VS.
Ergonomically sound, lightweight unit
is well balanced for ease of carrying to
remote welding sites. Fits through a 14 in
(25 mm) manhole/manway.
Digital meters with SunVision™
technology can display voltage and
wire speed, and also amperage
if desired. Meters can be seen
clearly even in direct sunlight
(8VS: Meters optional).
Polypropylene case with built-in slide
rails and the ability to open the door to
change wire with feeder in vertical position.
Wider voltage range for small
and large wires with no contactor
chatter or arc outages.
Potted and trayed main printed circuit
board for the harshest environments
adds exceptional reliability. Board has
full-trigger isolation so a shorted gun
trigger will not affect feeder operation.
Double-filtered gas valve helps
keep dirt from clogging and
affecting gas flow.
Excellent starts and improved
superior arc performance for all
types and sizes of wires whether
using CV or CC power supply.
Improved contactor for high-amperage,
high duty cycle applications (8VS: 330 A
at 60%,12VS: 425 A at 60%).
Specifications
Model
Input Power
8VS
Operates on
open-circuit
voltage and
arc voltage:
14 – 48 VDC/
110 Max OCV
12VS
Trigger hold, wire jog, and
gas purge are all located on front
panel (8VS: Trigger Hold optional).
(Use with CC/CV,
DC Power Sources.)
(Subject to change without notice.)
Welding Power
Source Type
Input Welding
Circuit Rating
Electrode Wire
Diameter Capacity
Max. Spool
Size Capacity
CC or CV DC power
sources. AC type
not recommended.
330 A at
60% Duty
Cycle
Solid Wire: .023– .062 in (0.6–1.6 mm)
Flux Cored: .030– .062 in (0.8–1.6 mm)
8 in (203 mm)
14 lb (6.4 kg)
CC or CV DC
power sources.
AC type not
recommended.
425 A at
60% Duty
Cycle
Solid Wire: .023– 5/64 in (0.6–2.0 mm)
Flux Cored: .030– 5/64 in (0.8–2.0 mm)
12 in (305 mm)
Up to 45 lb
(20.4 kg)
Net
Weight
Wire Speed
Dimensions
50–780 IPM
(1.3–19.8
m/min)
dependent
on arc
voltage
H: 12-3/4 in (324 mm) 28 lb
W: 7-1/4 in (184 mm) (13 kg)
D: 18 in (457 mm)
H: 21 in (533 mm)
35 lb
W: 9 in (229 mm)
(15.9 kg)
D: 15-1/2 in (394 mm)
Wire feeder is warranted for 3 years, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Control Panels
Drive Roll Kits
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits
include 2 drive rolls, the necessary guides and feature an anti-wear inlet guide.
3
4
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
“V” knurled
for hard-shelled
cored wires
“U” cogged for
extremely soft wire
or soft- shelled cored
wires (i.e., hard
facing types)
.023 / .025 in (0.6 mm)
#087 131
—
—
—
.030 in (0.8 mm)
#079 594
—
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
—
.040 in (1.0 mm)
#161 189
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599
#079 607
#083 318
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
#083 317
1/16 in (1.6 mm)
#079 598
#079 601
#079 609
#079 614
.068/.072 in (1.8 mm)
—
—
#089 984
—
5/64 in (2.0 mm)
—
#079 602
#079 610
#079 615
1
OFF
5
2
6
SuitCase X-TREME 8VS
1.
2.
3.
4.
Wire Speed Control
Jog/Purge Switch
Voltmeter (Optional)
Wire Speed/Amperage Meter
(Optional)
5. Trigger Hold Switch (Optional)
6. Power Control Switch
Ordering Information
Power Source and Options
Stock No.
5
SuitCase™ X-TREME™ 8VS
6
Meter Kit
Trigger Hold
With Bernard® Q300 Gun
(Without meters or trigger hold)
#300 093-01-1 With Bernard® Q300 Gun & meters
#300 093-02-1 With Bernard® Q300 Gun, meters & trigger hold
#300 331
Field. For X-TREME 8VS
#300 332
Field. For X-TREME 8VS
SuitCase™ X-TREME™ 12VS
SuitCase™ X-TREME™ 12VS
Flowmeter Kit
Inline Filter
Spool Adapter
#195 500
#300 414
#195 217
#195 189
#047 141
OFF
1
2
3
4
Front Panel
SuitCase X-TREME 12VS
1.
2.
3.
4.
5.
6.
Jog/Purge Switch
Voltmeter
Wire Speed/Amperage Meter
Wire Speed Control
Trigger Hold Switch
Power Control Switch
Qty.
With Bernard® Q300 Gun
With Bernard® Dura-Flux™ gun
For 14 lb spools/X-TREME 12VS only
Guns
Bernard® Q300 (GMAW)
Bernard® Dura-Flux™ (FCAW)
Ironmate™ 1260 (FCAW)
Roughneck® C-Series (GMAW)
See Welding Components and Parts Guide
See Welding Components and Parts Guide
See Lit. Index No. AY/16.0
See Lit. Index No. AY/17.0
Power Sources
XMT® Series
Dimension™
Gold Star®
Mark VI™
Big Blue® Turbo
Big Blue® 400 & 500
Big Blue® Air Pak™
Bobcat™
Trailblazer®
See Lit. Index No. DC/18.8
See Lit. Index No. DC/19.2
See Lit. Index No. DC/8.1
See Lit. Index No. DC/9.8
See Lit. Index No. ED/10.3
See Lit. Index No. ED/10.8
See Lit. Index No. ED/10.5
See Lit. Index No. ED/4.4
See Lit. Index No. ED/4.77
Consumables
Drive Rolls
Wire
Date:
Distributed by:
Litho in USA
Description
#300 093
Total Quoted Price:
Price

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