Академический Документы
Профессиональный Документы
Культура Документы
204 408K
200608
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Millermatic
135/175
And M-10 Gun
R
www.MillerWelds.com
Mil_Thank 200504
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 SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utiliss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Weld Parameter Chart For 115 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Weld Parameter Chart For 230 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
4
5
5
5
7
7
8
8
9
9
10
11
12
12
12
12
13
13
14
15
16
17
17
18
19
19
20
22
24
24
24
24
25
25
26
27
28
29
TABLE OF CONTENTS
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
31
31
32
33
34
35
35
35
36
36
37
37
37
38
38
38
39
40
Y Warning: Protect yourself and others from injury read and follow these precautions.
D
D
D
D
D
D
D
D
D
D
D
D
OM-1324 Page 2
READ INSTRUCTIONS.
D Read Owners Manual before using or servicing unit.
D Use only genuine Miller/Hobart replacement
parts.
D
D
D
D
D
D
D
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).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
022699101 (phone: 6177703000, 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 022699101 (phone:
6177703000,website: www.nfpa.org).
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 Officesphone for Region 5, Chicago, is
3123532220,website: www.osha.gov).
OM-1324 Page 4
Y Avertissement : se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.
2-1.
Symboles utiliss
Symbole graphique davertissement ! Attention ! Cette procdure comporte des risques possibles ! Les dangers ventuels sont reprsents par les symboles graphiques joints.
D
D
D
D
trous.
Sisoler de la pice couper et du sol en utilisant des housses ou des
tapis assez grands afin dviter tout contact physique avec la pice
couper ou le sol.
Ne pas se servir de source lectrique courant lectrique dans les zones humides, dans les endroits confins ou l o on risque de tomber.
Se servir dune source lectrique courant lectrique UNIQUEMENT si
le procd de soudage le demande.
Si lutilisation dune source lectrique courant lectrique savre ncessaire, se servir de la fonction de tlcommande si lappareil en est
quip.
Dautres consignes de scurit sont ncessaires dans les conditions
suivantes : risques lectriques dans un environnement humide ou si lon
porte des vtements mouills ; sur des structures mtalliques telles que
sols, grilles ou chafaudages ; en position coince comme assise, genoux ou couche ; ou sil y a un risque lev de contact invitable ou
accidentel avec la pice souder ou le sol. Dans ces conditions, utiliser
les quipements suivants, dans lordre indiqu : 1) un poste souder DC
tension constante ( fil), 2) un poste souder DC manuel (lectrode)
ou 3) un poste souder AC tension vide rduite. Dans la plupart des
situations, lutilisation dun poste souder DC fil tension constante
est recommande. En outre, ne pas travailler seul !
Couper lalimentation ou arrter le moteur avant de procder
linstallation, la rparation ou lentretien de lappareil. Dverrouiller
lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
scurit).
Installer le poste correctement et le mettre la terre convenablement
selon les consignes du manuel de loprateur et les normes nationales,
provinciales et locales.
Toujours vrifier la terre du cordon dalimentation. Vrifier et sassurer
que le fil de terre du cordon dalimentation est bien raccord la borne
de terre du sectionneur ou que la fiche du cordon est raccorde une
prise correctement mise la terre.
En effectuant les raccordements dentre, fixer dabord le conducteur
de mise la terre appropri et contre-vrifier les connexions.
D
D
D
dcharger les condensateurs dalimentation selon les instructions indiques dans la partie Entretien avant de toucher les pices.
OM-1324 Page 5
LES RAYONS DARC peuvent entraner des brlures aux yeux et la peau.
Le rayonnement de larc du procd de soudage
gnre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brlures dans les yeux et sur la peau.
Des tincelles sont projetes pendant le soudage.
D Porter un casque de soudage approuv muni de verres filtrants appropri pour protger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 numr dans les normes de scurit).
D Porter des lunettes de scurit avec crans latraux mme sous votre casque.
D Avoir recours des crans protecteurs ou des rideaux pour
protger les autres contre les rayonnements les blouissements et
les tincelles ; prvenir toute personne sur les lieux de ne pas
regarder larc.
D Porter des vtements confectionns avec des matires rsistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
DES
PARTICULES
VOLANTES
peuvent blesser les yeux.
D Le soudage, lcaillement, le passage de la
pice la brosse en fil de fer, et le meulage
gnrent des tincelles et des particules
mtalliques volantes. Pendant la priode de
refroidissement des soudures, elles risquent
de projeter du laitier.
D Porter des lunettes de scurit avec crans latraux ou un cran
facial.
OM-1324 Page 6
2-3.
LE
RAYONNEMENT
HAUTE
FRQUENCE (HF) risque de provoquer
des interfrences.
SUR-
D
D
D
D
D
D
D
2-4.
2-5.
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 (tlphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
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 (tlphone :
617-770-3000, site Internet : www.nfpa.org).
2-6.
Information EMF
OM-1324 Page 8
SECTION 3 SPECIFICATIONS
3-1. Specifications
A. 115 VAC Model
Rated Welding
Output
90 A @ 18
Volts DC, 20%
Duty Cycle
30 135
63 A @ 21
Volts DC, 20%
Duty Cycle*
Solid
Wire Type
And Dia
Maximum
Open-Circuit
Voltage DC
Amperage Range
KVA
KW
20
2.88
2.40
15*
2.20*
1.77*
28
Stainless
.024 - .030 in
(0.6 - 0.8
mm)
Amperes Input at
Rated Load Output 115 V, 60 Hz,
Single-Phase
.023 - .030 in
(0.6 - 0.8
mm)
Weight
W/ Gun
60 lb
(27 kg)
Overall
Dimensions
Length: 17-1/2 in
(444 mm)
Width: 10-5/8 in
(273 mm)
Height: 15-3/4 in
(400 mm)
Flux Cored
.030 - .035 in
(0.8 - 0.9 mm)
* CSA Rating
130 A @ 20 Volts
DC, 30% Duty Cycle
At 60 Hz Input
Amperage
Range
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)
30 175
30
19.5
4.60
3.75
73 lb
(33.0 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)
OM-1324 Page 9
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
120
Output Amperes
A. 115 VAC
Model
100
RatedOutput
80
60
40
20
0
10
20
30
40
50
60
70
80
90
100
Duty Cycle %
20% duty cycle at 90 amps
2 Minutes Welding
B. 230 VAC
Model
8 Minutes Resting
200
180
Output Amperes
160
140
120
100
80
60
40
20
0
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Duty Cycle %
3 Minutes Welding
7 Minutes Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 203 771 / 203 796
OM-1324 Page 10
30
25
VOLTAGE
20
Voltage Control @ 0
Voltage Control @ 1
Voltage Control @ 2
Voltage Control @ 3
Voltage Control @ 4
Voltage Control @ 5
Voltage Control @ 6
Voltage Control @ 7
Voltage Control @ 8
Voltage Control @ 9
Voltage Control @ 10
15
10
0.0
10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100. 110. 120. 130.
AMPERAGE
35
30
VOLTAGE
25
20
Voltage Control @ 0
Voltage Control @ 1
Voltage Control @ 2
Voltage Control @ 3
Voltage Control @ 4
Voltage Control @ 5
Voltage Control @ 6
Voltage Control @ 7
Voltage Control @ 8
Voltage Control @ 9
Voltage Control @ 10
15
10
5
0
AMPERAGE
OM-1324 Page 11
SECTION 4 INSTALLATION
4-1. Installing Welding Gun
1
2
3
Drive Assembly
Gun Securing Knob
Gun End
Close door.
3
1
2
Nut
Work Cable From Unit
Work Clamp
Screw
Work Clamp Tabs
5
3/8, 7/16 in
802 456
Work Cable
Output Terminal Block
OM-1324 Page 12
Cable Connections
Polarity
Cable To Gun
Cable To Work
Connect to negative ()
output terminal
C H A N G IN G P O L A R IT Y
DCEP
Electrode
ElectrodePOSITIVE
Positive
FOR SOLID WIRE
WorkClamp
Lead
Close door.
DCEN
Electrode Negative
Flux Core Wire
WorkClamp
Lead
2
Wire Drive
Lead
Wire Drive
Lead
OM-1324 Page 13
1
4
2
7
Cap
Cylinder Valve
Cylinder
Regulator/Flowmeter
Regulator/Flowmeter Gas
Hose Connection
Flow Adjust
Tools Needed:
5/8, 1-1/8 in
Ref. 802 028 / 802 441
OM-1324 Page 14
4-7. Selecting A Location And Connecting Input Power For 115 VAC Model
1
2
2
1
Rating Label
Grounded Receptacle
18 in
(460 mm)
18 in
(460 mm)
Ref. 802 980
OM-1324 Page 15
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.
18 in (457 mm) of
space for airflow
1
6
1
2
3
5
4
5
6
2
3
L1
L2
Rating Label
Over-Current Protection
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
230 VAC, 1
Tools Needed:
802 980 / Ref. 802 443 / Ref. 802 085 / 803 766-B
OM-1324 Page 16
230
20
25
Normal Operating 3
30
14
67
(20)
14
Tools Needed:
OM-1324 Page 17
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Gun Conduit Cable
Tools Needed:
4 in
(102 mm)
6 in
(150 mm)
Open pressure assembly.
Tighten
1
2
3
4
Pressure
Indicator
Scale
INPUT
POWER
Be sure that wire is positioned
in proper feed roll groove.
Close and tighten pressure
assembly, and let go of wire.
Tighten
WOOD
Press gun trigger until wire comes
out of gun.
1
2
3
4
OM-1324 Page 18
SECTION 5 OPERATION
5-1. Controls
1
2 Voltage Control
Turn control clockwise to increase voltage
(see weld parameter chart in welding
power source or Sections 5-2 and 5-3, as
applicable).
Power Switch
OM-1324 Page 19
Selecting
Note:
Wire,
Gas
and Control
1. Settings
are approximate.
Adjust as required.
2. Means
not recommended.
3. Thicker
materials
can be welded
using proper
joint preparation
and multiple
passes.
Material
What
Are you
Welding
Steel
Stainless
Steel
Suggested
Suggested
Wire
Shielding
Types,
technique,
Wire
Gases
Rate
Settings
Sizes
(Diameters)
Polarity
(Flow
Solid
Wire
(or Hard)
ER70S6
(DCEP)
C 25 Gas Mixture
75% Ar / 25% CO 2
(Ar / CO 2 produces
less
spatter
better
overall
appearance)
.024
( 0.6
mm
.030
( 0.8
mm
Solid
Wire
(or Hard)
ER70S6
(DCEP)
100%
.024
( 0.6
mm
.030
( 0.8
mm
Flux
Core
E71T11
(DCEN)
No Shielding
Gas
required.
Good
for windy
or outdoor
applications.
.030
( 0.8
mm
.035
( 0.9
mm
Stainless
Steel
(DCEP)
TriMix
90% He
.024
( 0.6
mm
.030
( 0.8
mm
of 2030
cfh)
CO 2
/ 7.5%
Ar
/ 2.5%
CO 2
Match feedroll groove to diameter of wire being used. Set Tension knob setting to 3 at start.
Adjust tension per instructions in the manual.
M10 (#195605) Torch Consumables:
Nozzles:
Tip Adapter:
#169715
#169716
Contact Tips:
.024 (0.6 mm) #087299
.030 (0.8 mm) #000067
.035 (0.9 mm) #000068
Liners:
.024
(0.6 mm)
#194010
.030 .035 (0.8 0.9 mm) #194011
.035 .045 (0.9 1.2 mm) #194012
OM-1324 Page 20
Diameters
(0.6 mm)
(0.8 mm)
(0.9 mm)
VSmooth
#220179
#220179
#220179
VKnurled *
#202926
#202926
Select
Voltage
Number
is Voltage
and
mm)
Speed
Based
of slash
Number
Knob
Setting.
is Wire
1/8
(3.2
mm)
16
(1.6
of Metal
on Thickness
on left
3/16
(4.8
Wire
ga.
mm)
on right
Speed
(0.9
Welded
of slash
Knob
20
Being
ga.
mm)
Setting.
24
(0.8
ga.
mm)
10 / 75
4.5 / 60
3 / 45
2 / 40
10 / 60
4 / 45
3 / 35
2 / 30
10 / 60
5 / 50
4 / 40
10 / 40
5 / 30
4 / 25
10 / 60
6 / 55
2.5 / 45
6 / 45
2.5 / 40
10 / 75
6 / 60
4 / 45
10 / 60
6 / 45
4 / 35
10/45
208 267
OM-1324 Page 21
Selecting
Note:
Wire,
Gas
and
Control
1. Settings
are approximate.
Adjust as required.
2. Means
not recommended.
3. Thicker
materials
can be welded
using proper
joint preparation
and multiple
passes.
Material
What
Are you
Welding
Steel
Stainless
Steel
Suggested
Suggested
Wire
Shielding
Types,
Settings
technique,
Wire
Gases
(Diameters)
Polarity
(Flow
Solid
Wire
(or Hard)
ER70S6
(DCEP)
C 25 Gas Mixture
75% Ar / 25% CO 2
(Ar / CO 2 produces
less
better
overall
spatter
appearance)
.024
( 0.6
mm
.030
( 0.8
mm
.035
( 0.9
mm
Solid
Wire
(or Hard)
ER70S6
(DCEP)
100%
.024
( 0.6
mm
.030
( 0.8
mm
.035
( 0.9
mm
Flux
Core
E71T11
(DCEN)
No Shielding
Gas
required.
Good
for windy
or outdoor
applications.
.030
( 0.8
mm
.035
( 0.9
mm
.045
( 1.2
mm
.024
( 0.6
mm
.030
( 0.8
mm
.035
( 0.9
mm
Stainless
Steel
(DCEP)
Rate
Sizes
of 2030
cfh)
CO 2
TriMix
90% He
/ 7.5%
Ar
/ 2.5%
CO 2
Match feedroll groove to diameter of wire being used. Set Tension knob setting to 3 at start.
Adjust tension per instructions in the manual.
M10 (#195605)
Nozzles:
#169715
Torch Consumables:
Tip Adapter:
#169716
Contact Tips:
.024 (0.6 mm)
.030 (0.8 mm)
.035 (0.9 mm)
.045 (1.2 mm)
#087299
#000067
#000068
#000069
Liners:
.024
.030 .035
.035 .045
.035 .045
(0.6 mm)
#194010
(0.8 0.9 mm) #194011
(0.9 1.2 mm) #194012
(0.9 1.2 mm) #194012
OM-1324 Page 22
Diameters
(0.6 mm)
(0.8 mm)
(0.9 mm)
(1.2 mm)
VSmooth
#220179
#220179
#220179
VKnurled *
#202926
#202926
#202926
Select
Voltage
Number
is Voltage
1/4
(6.4
mm)
and
Wire
Speed
Based
on Thickness
on left
of slash
Number
Knob
Setting.
is Wire
3/16
(4.8
mm)
1/8
(3.2
mm)
16
(1.6
of Metal
on right
Speed
ga.
mm)
Being
Welded
of slash
Knob
20
(0.9
Setting.
ga.
mm)
24
(0.8
ga.
mm)
10 / 100
6 / 100
4.5 / 85
3.5 / 70
2.5 / 50
1.5 / 40
10 / 75
6 / 70
4.5 / 60
3 / 45
2 / 35
1.5 / 30
10 / 70
6 / 55
4.5 / 50
3 / 40
1.5 / 30
10 / 75
6.5 / 70
4 / 40
3 / 25
10 / 55
8.5 / 55
6 / 50
4 / 40
3 / 25
10 / 45
7.5 / 45
5.5 / 45
3.5 / 35
3 / 20
6 / 75
4 / 70
3 / 65
1 / 50
5.5 / 65
4 / 55
3 / 50
1 / 40
7.5 / 40
6 / 40
3 / 35
10 / 80
6 / 70
4 / 50
2.5 / 50
10 / 70
6 / 65
4 / 45
2.5 / 35
10 / 60
6 / 55
3.5 / 35
208 268
OM-1324 Page 23
3 Months
Replace
unreadable
labels.
Repair or
replace
cracked
weld cable.
Clean and
tighten weld
terminals.
6 Months
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
Or
802 441
Stamped .024
Retaining Pin
.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
Nozzle
Contact Tip
1
Tools Needed:
OM-1324 Page 25
Head Tube
10 mm
Remove liner.
To Reassemble Gun:
Install and tighten new liner.
OM-1324 Page 26
Remove handle
locking nut.
3
2
Slide handle.
4 Secure head
tube in vice.
Tools Needed:
19 mm
OM-1324 Page 27
Trouble
Remedy
No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 4-7).
does not run
run.
Replace building line fuse or reset circuit breaker if open.
Place Power switch in On position (see Section 5-1).
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
motor continues to run.
unit has cooled (see Section 3-2).
Secure gun trigger leads (see Section 4-1).
No weld output; wire feeds.
Connect unit to proper input voltage or check for low line voltage.
Place voltage switch in desired position (see Section 5-1).
Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts.
welding
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).
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 leads or repair leads (see Section 4-1).
Check and clear any restrictions at drive assembly and liner (see Section 4-11 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-1324 Page 28
203 765
203 794
Regulator/
Flowmeter
Wire Feeder/
Power Source
Shielding Gas
Gas Hose
Gun
Work Clamp
Workpiece
OM-1324 Page 31
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.
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
Wire
Size
Recommendation
Wire Speed
(Approx.)
.023 in
.030 in
.035 in
Select Voltage
OM-1324 Page 32
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
2
3
4
5
0-15
90
90
GROOVE WELDS
0-15
45
45
FILLET WELDS
S-0421-A
OM-1324 Page 33
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
Short
Normal
Long
Short
Normal
Long
Slow
Normal
GUN TRAVEL SPEED
OM-1324 Page 34
Fast
S-0634
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
3
S-0054-A
1
2
3
4
5
5
S-0053-A
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
No Overlap
Good Penetration into Base
Metal
5
S-0052-B
OM-1324 Page 35
S-0636
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Wrong polarity.
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturers
recommended polarity, and see Section 4-4.
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.
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).
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 manufacturers
recommended polarity, and see Section 4-4.
OM-1324 Page 36
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 manufacturers
recommended polarity, and see Section 4-4.
Good Penetration
S-0638
Possible Causes
Corrective Actions
Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
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 manufacturers
recommended polarity, and see Section 4-4.
S-0637
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Wrong polarity.
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturers
recommended polarity, and see Section 4-4.
OM-1324 Page 37
S-0640
Possible Causes
Corrective Actions
Wrong polarity.
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturers
recommended polarity, and see Section 4-4.
S-0641
Possible Causes
Corrective Actions
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Unsteady hand.
S-0642
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-1324 Page 38
Short Circuiting
Stainless Steel
Short Circuiting
Aluminum
All Positions
Argon
Argon + 25% CO2
All Positions
CO2
All Positions
Tri-Mix3
Globular Transfer
All Positions2
All Positions
OM-1324 Page 39
21
22
20
12
13
10
29
42
44
33
31
25
30
30
35
34 39
37 36
38
28
27
11
26
40 41
43
14
15
16
23
18
24
17
19
32
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . BASE, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WRAPPER, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DOOR, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, control panel (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, control panel (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HINGE, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF support PC board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER ASSY (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER ASSY (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR (positive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR (negative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 53,000 uf (115 VAC model) . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 100,000 uf (230 VAC model) . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SUPPLEMENTARY PROTECTOR, 25 amp . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CORD SET, 125V 515P 14GA 3/C 7ft SPT3 jkt (115 VAC model) . . .
. . CORD SET, 250V 650P 12GA 3/C 7ft SPT3 jkt (230 VAC model) . . .
. . HANDLE, carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE, 2 way (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE, 2 way (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, fan (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, fan (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLADE, fan cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STABILIZER, 90A (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STABILIZER, 130A (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, pvc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WORK CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, rocker SPST (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, rocker DPDT (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LED, yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . POTENTIOMETER, cp flat 1T .50W 50k . . . . . . . . . . . . . . . . . . . . . . . . . .
. . POTENTIOMETER, cp flat 1T .50W 50k . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1324 Page 41
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1324 Page 42
804 095-A
Dia.
Mkgs.
Part
No.
223 655
... 1 ...............
... 2 ...............
... 3 ...............
... 4 ...............
... 5 ...............
... 6 ...............
... 7 ...............
... 8 ...............
... 9 ...............
. . . 10 . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . .
. . . 15 . . . . . DM . . . . .
. . . 16 . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . .
.....................
202 500
203 424
058 549
196 895
090 415
198 080
225 718
197 172
203 567
222 035
203 301
189 915
602 238
122 210
202 708
196 009
203 418
220 179
203 667
053 300
225 717
Description
Quantity
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1324 Page 43
6
7
14
10
15
11
13
12
802 388-B
OM-1324 Page 44
Item
No.
Part
No.
Description
Quantity
1
2
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14
14
14
15
. . . . . . . . . . . . . . . 169 715
. . . . . . . . . . . . . 087 299
. . . . . . . . . . . . . 000 067
. . . . . . . . . . . . . 000 068
. . . . . . . . . . . . . 000 069
. . . . . . . . . . . . . . . 169 716
. . . . . . . . . . . . . . . 170 470
. . . . . . . . . . . . . . . 169 718
. . . . . . . . . . . . . . . 169 738
. . . . . . . . . . . . . . . 169 719
. . . . . . . . . . . . . . . 169 737
. . . . . . . . . . . . . . . 227 798
. . . . . . . . . . . . . . . 079 878
. . . . . . . . . . . . . . . 227 800
. . . . . . . . . . . . . . . 209 495
. . . . . . . . . . . . . . . 079 974
. . . . . . . . . . . . . 194 010
. . . . . . . . . . . . . 194 011
. . . . . . . . . . . . . 194 012
. . . . . . . . . . . . . . . 079 975
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
220 179
202 926
9-5. Options
PART NO.
DESCRIPTION
REMARKS
770 187
194 776
195 605
OM-1324 Page 45
Notes
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.
2.
*
*
*
*
*
*
*
*
*
3.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
4.
6 Months Batteries
5.
90 Days Parts
2.
3.
miller_warr 200601
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
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
PRINTED IN USA
International HeadquartersUSA
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