Miller Electric Millermatic 140 Auto Set Users Manual O225311c_mil

Millermatic 180 Millermatic180 Operator Manual

140 to the manual 011f87b8-0bc8-459f-9a74-47364b0b5614

2015-02-02

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Processes

OM-225 311C 2007−05

Arc Welding Power Source And

Wire Feeder

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Millermatic 140,

140 Auto−Set , And 180

And M-10 Gun

File: MIG (GMAW)

Visit our website at

www.MillerWelds.com



Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. We know you don’t have time to do

it any other way.

That’s why when Niels Miller first started building arc welders in 1929,

he made sure his products offered long-lasting value and superior

quality. Like you, his customers couldn’t afford anything less. Miller

products had to be more than the best they could be. They had to be the

best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001:2000 Quality

System Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 2005−04

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symboles utilisés 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 . . . . . .

2-4. Proposition californienne 65 Avertissements 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Information EMF 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − SPECIFICATIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle And Overheating 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Volt-Ampere Curves 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Installing Welding Gun 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Installing Work Clamp 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Work Cable Routing Inside Unit 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Process/Polarity Table 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Changing Polarity 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Installing Gas Supply 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Selecting A Location And Connecting Input Power For 115 VAC Model 15 . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Selecting A Location And Connecting Input Power For 230 VAC Model 16 . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Electrical Service Guide For 230 VAC Model 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Installing Wire Spool And Adjusting Hub Tension 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Threading Welding Wire 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Removing MIG Gun From Welding Power Source 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. Installing Optional Spool Gun Switch In Welding Power Source 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14. Connecting Spool Gun To Millermatic 140/180 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Controls For 115 VAC Model w/Auto-Sett22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Controls For 115 VAC Model 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Controls For 230 VAC Model 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Weld Parameter Chart For 115 VAC Model w/Auto−Sett26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Weld Parameter Chart For 115 VAC Model w/Factory Set

Non-Wire Speed Tracking Mode 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Weld Parameter Chart For 115 VAC Model w/Wire Speed Tracking Mode 30 . . . . . . . . . . . . . . . . . . . . . .

5-7. Weld Parameter Chart For 230 VAC Model w/Factory Set

Non-Wire Speed Tracking Mode 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Weld Parameter Chart For 230 VAC Model w/Wire Speed Tracking Mode 34 . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 6 − MAINTENANCE &TROUBLESHOOTING 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Overload Protection 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Drive Motor Protection And Tip Saver/Short Circuit Protection 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Changing Drive Roll Or Wire Inlet Guide 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Replacing Gun Contact Tip 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Cleaning Or Replacing Gun Liner 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Replacing Switch And/Or Head Tube 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Troubleshooting Table 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAM 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − MIG WELDING (GMAW) GUIDELINES 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Typical MIG Process Connections 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Typical MIG Process Control Settings 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Holding And Positioning Welding Gun 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Conditions That Affect Weld Bead Shape 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Gun Movement During Welding 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Poor Weld Bead Characteristics 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Good Weld Bead Characteristics 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Troubleshooting − Excessive Spatter 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Troubleshooting − Porosity 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Troubleshooting − Excessive Penetration 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Troubleshooting − Lack Of Penetration 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-12. Troubleshooting − Incomplete Fusion 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-13. Troubleshooting − Burn-Through 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-14. Troubleshooting − Waviness Of Bead 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-15. Troubleshooting − Distortion 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-16. Common MIG Shielding Gases 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-225 311 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _3/05

YWarning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

YMarks a special safety message.

.Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Arc Welding Hazards

YThe symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

the Safety Standards listed in Section 1-5. Read and follow all

Safety Standards.

YOnly qualified persons should install, operate, maintain, and

repair this unit.

YDuring operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

DDo not touch live electrical parts.

DWear dry, hole-free insulating gloves and body protection.

DInsulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

DDo not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

DUse AC output ONLY if required for the welding process.

DIf AC output is required, use remote output control if present on

unit.

DAdditional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, or lying; or when there is a high risk of unavoid-

able or accidental contact with the workpiece or ground. For these

conditions, use the following equipment in order presented: 1) a

semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

DDisconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

DProperly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

DAlways verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

DWhen making input connections, attach proper grounding conduc-

tor first − double-check connections.

DFrequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

DTurn off all equipment when not in use.

DDo not use worn, damaged, undersized, or poorly spliced cables.

DDo not drape cables over your body.

DIf earth grounding of the workpiece is required, ground it directly

with a separate cable.

DDo not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

DDo not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

DUse only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

DWear a safety harness if working above floor level.

DKeep all panels and covers securely in place.

DClamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

DInsulate work clamp when not connected to workpiece to prevent

contact with any metal object.

DDo not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-type

welding power sources after removal of input

power.

DTurn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

DKeep your head out of the fumes. Do not breathe the fumes.

DIf inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

DIf ventilation is poor, wear an approved air-supplied respirator.

DRead and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,

coatings, cleaners, and degreasers.

DWork in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

DDo not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

DDo not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

OM-225 311 Page 2

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

ARC RAYS can burn eyes and skin.

DWear an approved welding helmet fitted with a proper shade of fil-

ter lenses to protect your face and eyes when welding or watching

(see ANSI Z49.1 and Z87.1 listed in Safety Standards).

DWear approved safety glasses with side shields under your

helmet.

DUse protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

DWear protective clothing made from durable, flame-resistant mate-

rial (leather, heavy cotton, or wool) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

DRemove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

DDo not weld where flying sparks can strike flammable material.

DProtect yourself and others from flying sparks and hot metal.

DBe alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

DWatch for fire, and keep a fire extinguisher nearby.

DBe aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

DDo not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

DConnect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock, sparks, and fire

hazards.

DDo not use welder to thaw frozen pipes.

DRemove stick electrode from holder or cut off welding wire at

contact tip when not in use.

DWear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

DRemove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

DFollow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL can injure eyes.

DWelding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

DWear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

DShut off shielding gas supply when not in use.

DAlways ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

DAllow cooling period before working on gun or

torch.

DTo handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

MAGNETIC FIELDS can affect pacemakers.

DPacemaker wearers keep away.

DWearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

DWear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

DProtect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

DInstall cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

DKeep cylinders away from any welding or other electrical circuits.

DNever drape a welding torch over a gas cylinder.

DNever allow a welding electrode to touch any cylinder.

DNever weld on a pressurized cylinder − explosion will result.

DUse only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

DTurn face away from valve outlet when opening cylinder valve.

DKeep protective cap in place over valve except when cylinder is in

use or connected for use.

DUse the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

DRead and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

OM-225 311 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

DDo not install or place unit on, over, or near

combustible surfaces.

DDo not install unit near flammables.

DDo not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

DUse equipment of adequate capacity to lift and

support unit.

DIf using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before

starting to weld again.

DDo not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

DUse proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

DKeep away from moving parts.

DKeep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

DDo not press gun trigger until instructed to do

so.

DDo not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

DKeep away from moving parts such as fans.

DKeep all doors, panels, covers, and guards

closed and securely in place.

DHave only qualified persons remove doors,

panels, covers, or guards for maintenance as

necessary.

DReinstall doors, panels, covers, or guards

when maintenance is finished and before re-

connecting input power.

READ INSTRUCTIONS.

DRead Owner’s Manual before using or servic-

ing unit.

DUse only genuine Miller/Hobart replacement

parts.

H.F. RADIATION can cause interference.

DHigh-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

DHave only qualified persons familiar with

electronic equipment perform this installation.

DThe user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

DIf notified by the FCC about interference, stop using the

equipment at once.

DHave the installation regularly checked and maintained.

DKeep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

DElectromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

DBe sure all equipment in the welding area is

electromagnetically compatible.

DTo reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

DLocate welding operation 100 meters from any sensitive elec-

tronic equipment.

DBe sure this welding machine is installed and grounded

according to this manual.

DIf interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

YWelding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California Health &

Safety Code Section 25249.5 et seq.)

YBattery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

For Gasoline Engines:

YEngine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive

harm.

For Diesel Engines:

YDiesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

OM-225 311 Page 4

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting 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 Protec-

tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269−9101 (phone: 617−770−3000, website: www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1735 Jefferson Davis Highway,

Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-

site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:

800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-

ternational.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11

West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,

website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:

617−770−3000, website: www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there

are 10 Regional Offices−−phone for Region 5, Chicago, is

312−353−2220, website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor before welding or going near

welding operations. If cleared by your doctor, then following the above

procedures is recommended.

OM-225 311 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

som _3/05

YAvertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1. Symboles utilisés

Symbole graphique d’avertissement ! Attention ! Cette pro-

cédure comporte des risques possibles ! Les dangers éven-

tuels sont représentés par les symboles graphiques joints.

YIndique un message de sécurité particulier

.Signifie NOTE ; n’est pas relatif à la sécurité.

Ce groupe de symboles signifie Avertissement ! Attention ! Risques

d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES

CHAUDES. Consulter les symboles et les instructions afférentes

ci-dessous concernant les mesures à prendre pour supprimer

les dangers.

2-2. Dangers relatifs au soudage à l’arc

YLes symboles représentés ci-dessous sont utilisés dans ce manuel

pour attirer l’attention et identifier les dangers possibles. En

présence de l’un de ces symboles, prendre garde et suivre les

instructions afférentes pour éviter tout risque. Les instructions en

matière de sécurité indiquées ci-dessous ne constituent qu’un

sommaire des instructions de sécurité plus complètes fournies

dans les normes de sécurité énumérées dans la Section 2-5. Lire et

observer toutes les normes de sécurité.

YSeul un personnel qualifié est autorisé à installer, faire fonction-

ner, entretenir et réparer cet appareil.

YPendant le fonctionnement, maintenir à distance toutes les per-

sonnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut

entraîner la mort.

Le contact d’organes électriques sous tension peut

provoquer des accidents mortels ou des brûlures

graves. Le circuit de l’électrode et de la pièce est

sous tension lorsque le courant est délivré à la

sortie. Le circuit d’alimentation et les circuits internes de la machine

sont également sous tension lorsque l’alimentation est sur Marche.

Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de

commande du rouleau et toutes les parties métalliques en contact

avec le fil sont sous tension électrique. Un équipement installé ou mis

à la terre de manière incorrecte ou impropre constitue un danger.

DNe pas toucher aux pièces électriques sous tension.

DPorter des gants isolants et des vêtements de protection secs et sans

trous.

DS’isoler de la pièce à couper et du sol en utilisant des housses ou des

tapis assez grands afin d’éviter tout contact physique avec la pièce à

couper ou le sol.

DNe pas se servir de source électrique à courant électrique dans les zo-

nes humides, dans les endroits confinés ou là où on risque de tomber.

DSe servir d’une source électrique à courant électrique UNIQUEMENT si

le procédé de soudage le demande.

DSi l’utilisation d’une source électrique à courant électrique s’avère né-

cessaire, se servir de la fonction de télécommande si l’appareil en est

équipé.

DD’autres consignes de sécurité sont nécessaires dans les conditions

suivantes : risques électriques dans un environnement humide ou si l’on

porte des vêtements mouillés ; sur des structures métalliques telles que

sols, grilles ou échafaudages ; en position coincée comme assise, à ge-

noux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou

accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser

les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC

à tension constante (à fil), 2) un poste à souder DC manuel (électrode)

ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des

situations, l’utilisation d’un poste à souder DC à fil à tension constante

est recommandée. En outre, ne pas travailler seul !

DCouper l’alimentation ou arrêter le moteur avant de procéder

à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller

l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de

sécurité).

DInstaller le poste correctement et le mettre à la terre convenablement

selon les consignes du manuel de l’opérateur et les normes nationales,

provinciales et locales.

DToujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer

que le fil de terre du cordon d’alimentation est bien raccordé à la borne

de terre du sectionneur ou que la fiche du cordon est raccordée à une

prise correctement mise à la terre.

DEn effectuant les raccordements d’entrée, fixer d’abord le conducteur

de mise à la terre approprié et contre-vérifier les connexions.

DVérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il

n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu

peut entraîner la mort.

DL’équipement doit être hors tension lorsqu’il n’est pas utilisé.

DNe pas utiliser des câbles usés, endommagés, de grosseur insuffisante

ou mal épissés.

DNe pas enrouler les câbles autour du corps.

DSi la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct.

DNe pas toucher l’électrode quand on est en contact avec la pièce, la terre

ou une électrode provenant d’une autre machine.

DNe pas toucher des porte électrodes connectés à deux machines en

même temps à cause de la présence d’une tension à vide doublée.

DN’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformément à

ce manuel.

DPorter un harnais de sécurité si l’on doit travailler au-dessus du sol.

DS’assurer que tous les panneaux et couvercles sont correctement en

place.

DFixer le câble de retour de façon à obtenir un bon contact métal-métal

avec la pièce à souder ou la table de travail, le plus près possible de la

soudure.

DIsoler la pince de masse quand pas mis à la pièce pour éviter le contact

avec tout objet métallique.

DNe pas raccorder plus d’une électrode ou plus d’un câble de masse à

une même borne de sortie de soudage.

Il reste une TENSION DC NON NÉGLIGEABLE dans

les sources de soudage onduleur quand on a coupé

l’alimentation.

DArrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions indi-

quées dans la partie Entretien avant de toucher les pièces.

Le soudage génère des fumées et des gaz. Leur

inhalation peut être dangereuse pour la santé.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

DNe pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va-

peurs.

DÀ l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de

l’arc pour l’évacuation des fumées et des gaz de soudage.

DSi la ventilation est médiocre, porter un respirateur anti-vapeurs approu-

vé.

DLire et comprendre les spécifications de sécurité des matériaux (MSDS) et

les instructions du fabricant concernant les métaux, les consommables, les

revêtements, les nettoyants et les dégraisseurs.

DTravailler dans un espace fermé seulement s’il est bien ventilé ou en

portant un respirateur à alimentation d’air. Demander toujours à un sur-

veillant dûment formé de se tenir à proximité. Des fumées et des gaz de

soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provo-

quant des blessures ou des accidents mortels. S’assurer que l’air de

respiration ne présente aucun danger.

DNe pas souder dans des endroits situés à proximité d’opérations de dé-

graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de

l’arc peuvent réagir en présence de vapeurs et former des gaz haute-

ment toxiques et irritants.

DNe pas souder des métaux munis d’un revêtement, tels que l’acier gal-

vanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait

été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en

portant un respirateur à alimentation d’air. Les revêtements et tous les

métaux renfermant ces éléments peuvent dégager des fumées toxi-

ques en cas de soudage.

OM-225 311 Page 6

Le rayonnement de l’arc du procédé de soudage

génère des rayons visibles et invisibles intenses

(ultraviolets et infrarouges) susceptibles de provo-

quer des brûlures dans les yeux et sur la peau.

Des étincelles sont projetées pendant le soudage.

LES RAYONS D’ARC peuvent entraî-

ner des brûlures aux yeux et à la peau.

DPorter un casque de soudage approuvé muni de verres filtrants ap-

proprié pour protéger visage et yeux pendant le soudage (voir ANSI

Z49.1 et Z87.1 énuméré dans les normes de sécurité).

DPorter des lunettes de sécurité avec écrans latéraux même sous vo-

tre casque.

DAvoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements et

les étincelles ; prévenir toute personne sur les lieux de ne pas

regarder l’arc.

DPorter des vêtements confectionnés avec des matières résistantes

et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

Le soudage effectué sur des conteneurs fermés tels

que des réservoirs, tambours ou des conduites peut

provoquer leur éclatement. Des étincelles peuvent

être projetées de l’arc de soudure. La projection

d’étincelles, des pièces chaudes et des équipements chauds peuvent

provoquer des incendies et des brûlures. Le contact accidentel de

l’électrode avec des objets métalliques peut provoquer des étincelles,

une explosion, une surchauffe ou un incendie. Avant de commencer

le soudage, vérifier et s’assurer que l’endroit ne présente pas de

danger.

LE SOUDAGE peut provoquer un

incendie ou une explosion.

DDéplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi-

gneusement avec des protections homologuées.

DNe pas souder dans un endroit où des étincelles peuvent tomber sur

des substances inflammables.

DSe protéger, ainsi que toute autre personne travaillant sur les lieux,

contre les étincelles et le métal chaud.

DDes étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites

fissures et des ouvertures.

DAfin d’éliminer tout risque de feu, être vigilant et garder toujours un

extincteur à la portée de main.

DLe soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

DNe pas effectuer le soudage sur des conteneurs fermés tels que des

réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa-

rés correctement conformément à AWS F4.1 (voir les normes de

sécurité).

DBrancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une longue

distance par des chemins inconnus éventuels en provoquant des

risques d’électrocution, d’étincelles et d’incendie.

DNe pas utiliser le poste de soudage pour dégeler des conduites

gelées.

DEn cas de non-utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

DPorter des vêtements de protection exempts d’huile tels que des

gants en cuir, une veste résistante, des pantalons sans revers, des

bottes et un casque.

DAvant de souder, retirer toute substance combustible de ses poches

telles qu’un allumeur au butane ou des allumettes.

DSuivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B

pour travaux de soudage et prévoir un détecteur d’incendie et un ex-

tincteur à proximité.

DES PARTICULES VOLANTES

peuvent blesser les yeux.

DLe soudage, l’écaillement, le passage de la

pièce à la brosse en fil de fer, et le meulage

génèrent des étincelles et des particules

métalliques volantes. Pendant la période de

refroidissement des soudures, elles risquent

de projeter du laitier.

DPorter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES ACCUMULATIONS DE GAZ

risquent de provoquer des blessures

ou même la mort.

DFermer l’alimentation du gaz protecteur en cas

de non-utilisation.

DVeiller toujours à bien aérer les espaces confi-

nés ou se servir d’un respirateur d’adduction

d’air homologué.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

DNe pas toucher des parties chaudes à mains

nues.

DPrévoir une période de refroidissement avant

d’utiliser le pistolet ou la torche.

DNe pas toucher aux pièces chaudes, utiliser les outils recom-

mandés et porter des gants de soudage et des vêtements épais

pour éviter les brûlures.

LES CHAMPS MAGNÉTIQUES peuvent

affecter les stimulateurs cardiaques.

DPorteurs de stimulateur cardiaque, rester

à distance.

DLes porteurs d’un stimulateur cardiaque doi-

vent d’abord consulter leur médecin avant de

s’approcher des opérations de soudage à l’arc,

de gougeage ou de soudage par points.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut

affecter l’ouïe.

DPorter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

Des bouteilles de gaz protecteur contiennent du gaz

sous haute pression. Si une bouteille est endomma-

gée, elle peut exploser. Du fait que les bouteilles de

gaz font normalement partie du procédé de soudage,

les manipuler avec précaution.

DProtéger les bouteilles de gaz comprimé d’une chaleur excessi-

ve, des chocs mécaniques, des dommages physiques, du lai-

tier, des flammes ouvertes, des étincelles et des arcs.

DPlacer les bouteilles debout en les fixant dans un support sta-

tionnaire ou dans un porte-bouteilles pour les empêcher de tom-

ber ou de se renverser.

DTenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

DNe jamais placer une torche de soudage sur une bouteille à gaz.

DUne électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

DNe jamais souder une bouteille pressurisée − risque d’explosion.

DUtiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifi-

que ; les maintenir ainsi que les éléments associés en bon état.

DDétourner votre visage du détendeur-régulateur lorsque vous

ouvrez la soupape de la bouteille.

DLe couvercle du détendeur doit toujours être en place, sauf lors-

que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-

rieur.

DUtiliser les équipements corrects, les bonnes procédures et suf-

fisamment de personnes pour soulever et déplacer les bouteil-

les.

DLire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed

Gas Association) mentionné dans les principales normes de sécuri-

té.

LES BOUTEILLES peuvent exploser

si elles sont endommagées.

OM-225 311 Page 7

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanc

Risque D’INCENDIE OU D’EXPLO-

SION.

DNe pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

DNe pas installer l’appareil à proximité de

produits inflammables.

DNe pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant

de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut

blesser.

DUtiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les

bouteilles de gaz ou tout autre accessoire.

DUtiliser un équipement de levage de capacité

suffisante pour lever l’appareil.

DEn utilisant des fourches de levage pour déplacer l’unité, s’assu-

rer que les fourches sont suffisamment longues pour dépasser

du côté opposé de l’appareil.

L’EMPLOI EXCESSIF peut SUR-

CHAUFFER L’ÉQUIPEMENT.

DPrévoir une période de refroidissement ;

respecter le cycle opératoire nominal.

DRéduire le courant ou le facteur de marche

avant de poursuivre le soudage.

DNe pas obstruer les passages d’air du poste.

LES CHARGES ÉLECTROSTATIQUES

peuvent endommager les circuits

imprimés.

DÉtablir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

DUtiliser des pochettes et des boîtes antistati-

ques pour stocker, déplacer ou expédier des

cartes PC.

DES ORGANES MOBILES peuvent

provoquer des blessures.

DNe pas s’approcher des organes mobiles.

DNe pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

DNe pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

DNe pas diriger le pistolet vers soi, d’autres

personnes ou toute pièce mécanique en enga-

geant le fil de soudage.

DES ORGANES MOBILES peuvent

provoquer des blessures.

DS’abstenir de toucher des organes mobiles tels

que des ventilateurs.

DMaintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de

protection.

DSeules des personnes qualifiées sont autorisées à enlever les

portes, panneaux, recouvrements ou dispositifs de protection

pour l’entretien.

DRemettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher

l’alimentation électrique.

LIRE LES INSTRUCTIONS.

DLire le manuel d’utilisation avant d’utiliser ou

d’intervenir sur l’appareil.

DUtiliser uniquement des pièces de rechange

Miller/Hobart.

LE RAYONNEMENT HAUTE

FRÉQUENCE (HF) risque de provoquer

des interférences.

DLe rayonnement haute fréquence (HF) peut

provoquer des interférences avec les équipe-

ments de radio-navigation et de communica-

tion, les services de sécurité et les ordinateurs.

DDemander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal-

lation.

DL’utilisateur est tenu de faire corriger rapidement par un électri-

cien qualifié les interférences résultant de l’installation.

DSi le FCC signale des interférences, arrêter immédiatement

l’appareil.

DEffectuer régulièrement le contrôle et l’entretien de l’installation.

DMaintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une

distance correcte et utiliser une terre et un blindage pour réduire

les interférences éventuelles.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

DL’énergie électromagnétique peut gêner le

fonctionnement d’appareils électroniques

comme des ordinateurs et des robots.

DVeiller à ce que tout l’équipement de la zone de

soudage soit compatible électromagnétiquement.

DPour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser

aussi bas que possible (ex. par terre).

DVeiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

DVeiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

DEn cas d’interférences après avoir pris les mesures précéden-

tes, il incombe à l’utilisateur de prendre des mesures supplé-

mentaires telles que le déplacement du poste, l’utilisation de

câbles blindés, l’utilisation de filtres de ligne ou la pose de protec-

teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

YLes équipements de soudage et de coupage produisent des

fumées et des gaz qui contiennent des produits chimiques dont

l’État de Californie reconnaît qu’ils provoquent des malformations

congénitales et, dans certains cas, des cancers. (Code de santé et

de sécurité de Californie, chapitre 25249.5 et suivants)

YLes batteries, les bornes et autres accessoires contiennent du

plomb et des composés à base de plomb, produits chimiques

dont l’État de Californie reconnaît qu’ils provoquent des can-

cers et des malformations congénitales ou autres problèmes de

procréation. Se laver les mains après manipulation.

Pour les moteurs à essence :

YLes gaz d’échappement des moteurs contiennent des produits

chimiques dont l’État de Californie reconnaît qu’ils provoquent

des cancers et des malformations congénitales ou autres pro-

blèmes de procréation.

Pour les moteurs diesel :

YLes gaz d’échappement des moteurs diesel et certains de leurs

composants sont reconnus par l’État de Californie comme

provoquant des cancers et des malformations congénitales ou au-

tres problèmes de procréation.

OM-225 311 Page 8

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

de Global Engineering Documents (téléphone : 1-877-413-5184, site In-

ternet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard AWS

F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site

Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protection

Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite

1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet

: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :

800-463-6727 ou à Toronto 416-747-4044, site Internet :

www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, de American National Standards Institute, 11 West

42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site

Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, de National Fire Protection Association, P.O.

Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :

617-770-3000, site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and

Part 1926, Subpart J, de U.S. Government Printing Office, Superinten-

dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10

bureaux régionaux−−le téléphone de la région 5, Chicago, est

312-353-2220, site Internet : www.osha.gov).

2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des

champs magnétiques et électriques.

Le courant de soudage, pendant son passage dans les câbles de souda-

ge, causera des champs électromagnétiques. Il y a eu et il y a encore un

certain souci à propos de tels champs. Cependant, après avoir examiné

plus de 500 études qui ont été faites pendant une période de recherche

de 17 ans, un comité spécial ruban bleu du National Research Council a

conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a

pas démontré que l’exposition aux champs magnétiques et champs élec-

triques à haute fréquence représente un risque à la santé humaine ».

Toutefois, des études sont toujours en cours et les preuves continuent à

être examinées. En attendant que les conclusions finales de la recherche

soient établies, il vous serait souhaitable de réduire votre exposition aux

champs électromagnétiques pendant le soudage ou le coupage.

Pour réduire les champs magnétiques sur le poste de travail, appliquer

les procédures suivantes :

1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.

2. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4. Garder le poste de soudage et les câbles le plus loin possible de

vous.

5. Connecter la pince sur la pièce aussi près que possible de la sou-

dure.

En ce qui concerne les stimulateurs cardiaques

Les porteurs de stimulateur cardiaque doivent consulter leur médecin

avant de souder ou d’approcher des opérations de soudage. Si le méde-

cin approuve, il est recommandé de suivre les procédures précédentes.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 9

SECTION 3 − SPECIFICATIONS

3-1. Specifications

A. 115 VAC Model

Rated Welding

Output Amperage Range Maximum

Open-Circuit

Voltage DC

Amperes Input at

Rated Load Out-

put 115 V, 60 Hz,

Single-Phase

KVA KW Weight

W/ Gun Overall

Dimensions

90 A @ 18

Volts DC, 20%

Duty Cycle

63 A @ 21

Volts DC, 20%

Duty Cycle*

30 − 140 28

15*

2.8

2.1*

2.4

1.8*

60 lb

(27 kg)

Length: 17-1/2 in

(444 mm)

Width: 10-5/8 in

(273 mm)

Height: 15-3/4 in

(400 mm)

Solid Stainless Flux Cored Wire Feed Speed Range w/Wire Feed Speed Tracking On

Wire Type

And Dia .024 - .030 in

(0.6 - 0.8

mm)

.023 - .030 in

(0.6 - 0.8

mm)

.030 - .035 in

(0.8 - 0.9 mm) 45 − 500 IPM (1.1 − 12.7 m/min) At No Load

40 − 500 IPM (1.0 − 12.7 m/min) Feeding Wire

* CSA Rating

B. 115 VAC Model w/Auto−SetE

Rated Welding

Output Amperage Range Maximum

Open-Circuit

Voltage DC

Amperes Input at

Rated Load Out-

put 115 V, 60 Hz,

Single-Phase

KVA KW Weight

W/ Gun Overall

Dimensions

90 A @ 18

Volts DC, 20%

Duty Cycle

63 A @ 21

Volts DC, 20%

Duty Cycle*

30 − 140 28

15*

2.8

2.1*

2.4

1.8*

60 lb

(27 kg)

Length: 17-1/2 in

(444 mm)

Width: 10-5/8 in

(273 mm)

Height: 15-3/4 in

(400 mm)

Solid Stainless Flux Cored Wire Feed Speed Range

Wire Type

And Dia .024 - .030 in

(0.6 - 0.8

mm)

.023 - .030 in

(0.6 - 0.8

mm)

.030 - .035 in

(0.8 - 0.9 mm) 35 − 420 IPM (0.9 − 10.7 m/min) At No Load

15 − 390 IPM (0.4 − 9.9 m/min) Feeding Wire

* CSA Rating

C. 230 VAC Model

Rated Welding

Output Amperage

Range

Maximum Open-

Circuit Voltage

Amperes Input at

Rated Load Output

230 V, 60 Hz,

Single-Phase

KVA KW Weight

W/ Gun Overall

Dimensions

135 A @ 22.5 Volts

DC, 30% Duty Cycle

At 60 Hz Input 30 − 180 31 21.7 5.0 4.1 72 lb

(32.7 kg)

Length: 17-1/2 in

(444 mm)

Width: 10-5/8 in

(273 mm)

Height: 15-3/4 in

(400 mm)

Wire Type

And Dia

Solid/

Stainless Flux Cored Wire Feed Speed Range w/Wire Feed Speed Tracking On

Wire Type

And Dia .024 − .035 in

(0.6 − 0.9 mm) .030 − .045 in

(0.8 − 1.2 mm) 100 − 725 IPM (2.5 − 18.4 m/min) At No Load

90 − 700 IPM (2.3 − 17.8 m/min) Feeding Wire

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 10

3-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10

minutes that unit can weld at rated

load without overheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

duty cycle before welding.

YExceeding duty cycle can

damage unit or gun and void

warranty.

Overheating

A or V

Reduce Duty Cycle

Minutes

duty1 4/95 − 230 342-A / 230 343-A

A. 115 VAC

Model

B. 230 VAC

Model

3 Minutes Welding 7 Minutes Resting

20% duty cycle at 90 amps

30% duty cycle at 135 amps, 60 Hz

2 Minutes Welding 8 Minutes Resting

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 11

3-3. Volt-Ampere Curves

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities of

the welding power source. Curves

of other settings fall between the

curves shown.

225 265-A / 228 250-A

A. 115 VAC Model

B. 230 VAC Model

0 20406080100120140160

AMPERAGE

VOLTAGE

MAX

MIN

0 20 40 60 80 100 120 140 160 180 200

AMPERAGE

VOLTAGE

MAX

MIN

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 12

SECTION 4 − INSTALLATION

4-1. Installing Welding Gun

Ref. 802 982-A / Ref. 801 987

1 Drive Assembly

2 Gun Securing Knob

3 Gun End

Loosen knob. Insert gun end

through opening until it bottoms

against drive assembly. Tighten

knob.

4 Gun Trigger Plug

Insert into receptacle, and tighten

threaded collar.

Close door.

Correct Incorrect

.Be sure that gun end is tight against drive assembly.

4-2. Installing Work Clamp

1 Nut

2 Work Cable From Unit

3 Work Clamp

4 Screw

5 Work Clamp Tabs

Bend tabs around work cable.

6 Insulating Sleeves

Slide one insulating sleeve over

work cable before connecting to

clamp.

Slide insulating sleeves over

handles.

802 456-A

.Connection hardware must be tightened with proper tools. Do not just

hand tighten hardware. A loose electrical connection will cause poor

weld performance and excessive heating of the work clamp.

Tools Needed:

7/16 in

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 13

4-3. Work Cable Routing Inside Unit

Ref. 802 982-A

1 Work Cable

2 Output Terminal Block

Insert work cable through opening

in front panel and route along back

of front panel to output terminal

block.

Close door.

4-4. Process/Polarity Table

Process

Polarity

Cable Connections

Process

Polarity

Cable To Gun Cable To Work

GMAW − Solid wire with shield-

ing gas DCEP − Reverse polarity Connect to positive (+) out-

put terminal Connect to negative (−) output

terminal

FCAW − Self-shielding wire −

no shielding gas DCEN − Straight Polarity Connect to negative (−)

output terminal Connect to positive (+) output

terminal

4-5. Changing Polarity

1 Lead Connections For Direct

Current Electrode Positive

(DCEP)

2 Lead Connections For Direct

Current Electrode Negative

(DCEN)

Always read and follow wire

manufacturer’s recommended

polarity, and see Section 4-4.

Close door.

Ref. 203 501 / Ref. 802 982-

CHANGING POLARITY

DCEP

Electrode POSITIVE

FOR SOLID WIRE

DCEN

Electrode Negative

Flux Core Wire

Work Clamp

Le a d

Wire Drive

Le a d

WorkClamp

Le a d

Wire Drive

Le a d

CHANGING POLARITY

DCEP

Electrode Positive

FOR SOLID WIRE

DCEN

Electrode Negative

Flux Core Wire

Work Clamp

Le a d

Wire Drive

Le a d

WorkClamp

Le a d

Wire Drive

Le a d

.Connection hardware must be tightened with proper tools. Do not

just hand tighten hardware. A loose electrical connection will cause

poor weld performance and excessive heating at the terminal block.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 14

4-6. Installing Gas Supply

Obtain gas cylinder and chain to

running gear, wall, or other

stationary support so cylinder

cannot fall and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve,

and open valve slightly. Gas flow

blows dust and dirt from valve.

Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source Gas

Hose Connection

Connect supplied gas hose

between regulator/flowmeter gas

hose connection, and fitting on rear

of welding power source.

7 Flow Adjust

Typical flow rate is 20 cfh (cubic

feet per hour). Check wire

manufacturer’s recommended flow

rate.

Tools Needed:

Ref. 802 028 / 802 441

5/8, 1-1/8 in

Argon Gas Or

Mixed Gas

.DO NOT use Argon/Mixed gas regulator/flowmeter

with CO2 shielding gas. See Parts List for optional

CO2 gas regulator/flowmeter and hose.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 15

4-7. Selecting A Location And Connecting Input Power For 115 VAC Model

1 Rating Label

2 Grounded Receptacle

A 115 volt, 20 ampere individual

branch circuit protected by time-delay

fuses or circuit breaker is required.

3 Plug From Unit

Select extension cord of 14 AWG

for up to 50 ft (15 m) or 12 AWG for

50 up to 200 ft (61 m).

YSpecial installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

18 in

(460 mm)

804 681-A

118 in

(460 mm) 2

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 16

4-8. Selecting A Location And Connecting Input Power For 230 VAC Model

YInstallation must meet all Na-

tional and Local Codes − have

only qualified persons make

this installation.

YDisconnect and lockout/tag-

out input power before con-

necting input conductors from

unit.

YAlways connect green or

green/yellow conductor to

supply grounding terminal

first, and never to a line termi-

nal.

1 Rating Label

Supply correct input power.

2 Black And White Input

Conductor (L1 And L2)

3 Green Or Green/Yellow

Grounding Conductor

4 Input Power Cord.

5 Disconnect Device (switch

shown in the OFF position)

6 Disconnect Device Grounding

Terminal

7 Disconnect Device Line

Terminals

Connect green or green/yellow

grounding conductor to disconnect

device grounding terminal first.

Connect input conductors L1 and L2

to disconnect device line terminals.

8 Over-Current Protection

Select type and size of over-current

protection using Section 4-9 (fused

disconnect switch shown).

Close and secure door on disconnect

device. Remove lockout/tagout de-

vice, and place switch in the On posi-

tion.

9 Plug (NEMA 6-50P)

10 Receptacle (NEMA 6-50R)

Connect plug to receptacle.

YSpecial installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

Ref. 804 681-A / Ref. 802 443 / Ref. 802 085 / 803 766-B

18 in (457 mm) of

space for airflow

230 VAC, 1

YDo not move or operate unit

where it could tip.

Tools Needed:

=GND/PE Earth

Ground

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 17

4-9. Electrical Service Guide For 230 VAC Model

60 Hz

Single

Phase

Input Voltage 230

Input Amperes At Rated Output 21.7

Max Recommended Standard Fuse Rating In Amperes

Circuit Breaker 1, Time-Delay 225

Normal Operating 330

Min Input Conductor Size In AWG 414

Max Recommended Input Conductor Length In Feet (Meters) 61

(19)

Min Grounding Conductor Size In AWG 414

Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.

2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

YCaution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These

recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.

4-10. Installing Wire Spool And Adjusting Hub Tension

When a slight force is needed

to turn spool, tension is set.

1/2 in

Tools Needed:

803 012 / 803 013 -B / Ref. 802 444-C

Installing 8 in (203 mm) Wire Spool

Installing 4 in (102 mm) Wire Spool

When a slight force is needed

to turn spool, tension is set.

Retaining ring used

with 8 in (203 mm)

spool only.

Adapter used with

8 in (203 mm)

spool only.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 18

4-11. Threading Welding Wire

1 Wire Spool

2 Welding Wire

3 Inlet Wire Guide

4 Pressure Adjustment Knob

5 Drive Roll

6 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

Pull and hold wire; cut off end.

4 in

(102 mm)

Remove gun nozzle and contact tip.

Open pressure assembly. Push wire thru guides into gun;

continue to hold wire.

Be sure that wire is positioned in proper drive

roll groove and wire is laying in the groove.

.Hold wire tightly to keep it

from unraveling.

Ref. 802 982-A / Ref. 205 837

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close door.

Press gun trigger until wire comes

out of gun. Be sure that tip matches wire diameter.

Reinstall contact tip and nozzle.

Turn power on.

INPUT

POWER

Tighten

.Use pressure indicator scale to set a desired

drive roll pressure. Begin with a setting of 3.

If necessary, make additional adjustments

after trying this initial setting.

Pressure

Indicator

Scale

Tighten

6 in

(150 mm)

Close and tighten pressure

assembly, and let go of wire.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 19

4-12. Removing MIG Gun From Welding Power Source

Open Pressure Assembly

.Hold wire tightly to keep it

from unraveling.

Rewind Wire Onto Spool, Fasten

End Of Wire To Spool

Cut Off End Of Wire

Loosen Knob, Disconnect Gun Trigger

Plug, And Pull Gun From Unit

Ref. 802 982-A

Knob

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 20

4-13. Installing Optional Spool Gun Switch In Welding Power Source

Ref. 804 984-A / 804 892-A

Tools Needed:

1/4, 5/16 in 9/16 in

YTurn Off unit, and disconnect

input power.

.For units prior to Serial No.

LH210051N, use retrokit part

no. 234402 for installing spool

gun switch.

Remove wrapper from welding

power source.

1 Welding Power Source Center

Baffle

2 Snap-in Blank

Remove and discard snap-in blank

from hole in center baffle.

3 Switch Assembly

4 Star Washer

5 Jam Nut

Remove top jam nut and star wash-

er from switch (switch is equipped

with two nuts, a jam nut and a

backing nut).

Insert switch assembly into center

baffle so that keyway in switch shaft

is facing up.

Secure switch to center baffle with

star washer and jam nut. Tighten

jam nut enough to keep switch from

rotating.

6 Wiring Harness Connectors

7 Switch Connectors

8 Label

Locate and separate connectors in

wiring harness near label.

Connect switch connectors to

matching connectors in wiring

harness.

Install wrapper on unit.

Operation:

Place switch in the position with the

spool gun symbol on the label for

spool gun operation. Place switch in

the position with the MIG gun symbol

on the label for wire feeder/MIG

(GMAW) gun operation.

When the switch is in the spool gun

position, spool gun wire feed speed

and voltage are controlled by

welding power source controls.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 21

4-14. Connecting Spool Gun To Millermatic 140/180

804 984-A / Ref. 801 987

1 Drive Assembly

2 Spool Gun

3 Gun Securing Knob

4 Gun End

Loosen thumbscrew. Insert end

through opening until it bottoms

against drive assembly. Tighten

gun securing knob.

Spool gun must be inserted

completely to prevent leakage of

shielding gas.

5 Gun Trigger Plug

Insert plug into receptacle, and

tighten threaded collar.

6 Spool Gun/MIG Gun Switch

Place switch in Spool Gun position.

7 Polarity Changeover Terminal

Block

To make proper polarity connection,

see welding power source Owner’s

Manual.

Close door.

Incorrect

Gun Fully Seated

Gun Not Seated

Correct

.Be sure that gun end is tight against drive assembly.

Exposed O-rings

will cause shielding

gas leakage.

132

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 22

SECTION 5 − OPERATION

5-1. Controls For 115 VAC Model w/Auto-SetE

1 Wire Speed Control

Turn control clockwise inside white scale

(10-100) to increase wire feed speed. (see

weld parameter chart in welding power

source or Section 5-4, 5-5, 5-6, 5-7, or 5-8

as applicable).

2 Voltage Control

Turn control clockwise inside white scale

(1-10) to increase voltage (see weld

parameter chart in welding power source

or Section 5-4, 5-5, 5-6, ,5-7, or 5-8 as

applicable).

3 Power Switch

4 Over Temperature Light

5 Gun Trigger Receptacle

6 Auto−Set Light

To use Auto−Set mode, rotate Wire

Speed control inside blue area for the

applicable Weld Wire Diameter,

Auto−Set light will turn on, and the unit will

provide the appropriate wire feed speed for

the material thickness selected using the

Voltage control (see Section 5-4).

Rotate Voltage control inside blue scale (24

ga to 1/8”) for the applicable material

thickness and the unit will provide the

appropriate voltage within the range of the

selected material thickness and the selected

Weld Wire Diameter (see Section 5-4).

227 748-C

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 23

5-2. Controls For 115 VAC Model

1 Wire Speed Control

Turn control clockwise to increase wire

feed speed. (see weld parameter chart in

welding power source or Section 5-4, 5-5,

5-6, 5-7, or 5-8, as applicable).

2 Voltage Control

Turn control clockwise to increase voltage

(see weld parameter chart in welding

power source or Section 5-4, 5-5, 5-6, 5-7

or 5-8, as applicable).

3 Power Switch

4 Over Temperature Light

5 Gun Trigger Receptacle

225 226-C

OVERTEMP

TRIGGER

115VWireWelder



OFF

Welds24gaugeto3/16"MildSteel

POWER

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 24

5-3. Controls For 230 VAC Model

1 Wire Speed Control

Turn control clockwise to increase wire

feed speed. (see weld parameter chart in

welding power source or Section 5-5, 5-4,

5-6, 5-7 or 5-8, as applicable).

2 Voltage Control

Turn control clockwise to increase voltage

(see weld parameter chart in welding

power source or Section 5-5, 5-4, 5-6, 5-7

or 5-8 as applicable).

3 Power Switch

4 Over Temperature Light

5 Gun Trigger Receptacle

225 227-C

OVERTEMPTRIGGER

OFF

230VWireWelder

Welds24gaugeto5/16"MildSteel

POWER

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 25

Notes

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 26

5-4. Weld Parameter Chart For 115 VAC Model w/Auto−SetE

IMPORTANT: Match drive roll groove to diameter of wire being used.

Set Tension knob setting to 3 at start. Adjust tension

per instructions in the manual.

NOTE: Settings are approximate. Adjust as required.

“−−−” Means not recommended.

“*” Thicker materials can be welded using proper technique,

joint preparation and multiple passes.

Activate Auto−Sett by selecting

the diameter of the welding wire

with the WIRE SPEED knob.

Auto−Set light comes on.

Example: .030” diameter wire, welding 18 ga. material.

Select thickness of the mild steel

being welded with the VOLTAGE

knob.

Setup complete.

Auto−Sett − SIMPLE SETUP FOR WELDING MILD STEEL

(DCEP)

(DCEN)

(DCEP)

−

ettM

ATERIALTHIC

.024”

.030” WELD WIRE

DIAMETER

Auto−Set*

.030” (0.8 mm)

.035” (0.9 mm)

Aluminum w/

Opt. Spool Gun Aluminum

4043ER 100% Argon

Selecting Wire, Gas and Control Settings for Aluminum with optional Spool Gun. Order part no. 300371

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 27

227 931-H

Manual Setup

Refer to chart below to select Voltage and Wire Speed based

on thickness of metal being welded.

2. Number on left of

slash is Voltage

Knob Setting.

(Example: 4 / 65)

1. Number on right

of slash is Wire

Speed Knob Setting.

(Example: 4 / 65)

10/90

10/65

10/80

10/60

10/65

10/50 10/50

10/75

5.5/60

5.5/80

7/80

5.5/60

4.5/45

5/554/45

3/50

3/40

6/75

6/60

6.5/50

4.5/70

5.5/65

5.5/45

3/40

3/35

4/65

4/45

4/35 5/40

2.5/32

3/40

3/502/40

2/32

10/957/95

7/70

5/50

4.5/50

4/40

4.5/50

2/35

5/60

uto

−

10/1003/90

3/90 10/903/75

3/70

THIC

tMATERI A

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 28

5-5. Weld Parameter Chart For 115 VAC Model w/Factory Set

Non-Wire Speed Tracking Mode

1. Number on left of

slash is Voltage

Knob Setting.

(Example: 4.5 / 65)

2. Number on right

of slash is Wire

Speed Knob Setting.

(Example: 4.5 / 65)

Refer to chart below to select Voltage and Wire Speed based on

thickness of material being welded.

Solid Wire

ER70S−6

(DCEP)

Solid Wire

ER70S−6

(DCEP)

Flux Core

E71T−11

(DCEN)

Stainless

Steel

(DCEP)

Selecting Wire, Gas and Control Settings for Aluminum

.030” (0.8 mm)

.035” (0.9 mm)

Aluminum w/

Opt. Spool Gun Aluminum

4043ER 100% Argon

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 29

224 940-D

3/30

3.5/45

2.5/28

2.5/35

3/30

3.5/45

4.5/35

5/22

5/40

5/30

5.5/45

5.5/30

4.5/40

4/55

2/30

2/25

6/50

8/65

6.5/40

5.5/80

5.5/50

6/40

7.5/85

7/70

10/90

10/45

10/60

10/30

10/45

8/40 10/32

10/80

10/605/35

3.5/40

6/35

5.5/55

5/45

4.5/65

3.5/25

6.5/70

6/60

NOTE: Settings are approximate. Adjust as required.

“−−−” Means not recommended.

“*” Thicker materials can be welded using proper technique,

joint preparation and multiple passes.

IMPORTANT: Match drive roll groove to diameter of wire being used.

Set Tension knob setting to 3 at start. Adjust tension

per instructions in the manual.

224 940−D

10/753/702/60

10/703.5/65

3/60

with optional Spool Gun, Order part no. 300371

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 30

5-6. Weld Parameter Chart For 115 VAC Model w/Wire Speed Tracking Mode

1. Number on left of

slash is Voltage

Knob Setting.

(Example: 4.5/65)

2. Number on right

of slash is Wire

Speed Knob Setting.

(Example: 4.5 / 65)

Refer to chart below to select Voltage and Wire Speed based on

thickness of material being welded.

Solid Wire

ER70S−6

(DCEP)

Solid Wire

ER70S−6

(DCEP)

Flux Core

E71T−11

(DCEN)

Stainless

Steel

(DCEP)

To enable wire speed tracking, proceed as follows:

1. Turn Power switch off.

2. Rotate Voltage knob to minimum.

3. Rotate Wire Speed knob to maximum.

4. Hold gun trigger in while turning on Power switch.

.To verify wire speed tracking is on, open drive roll pressure arm, pull trigger,

and rotate Voltage knob from min. to max. Drive roll speed will change rpm

if tracking is on.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 31

232 016-A

3/30

3.5/45

2.5/28

2.5/35

3/30

3.5/45

4.5/35

5/22

5/40

5/30

5.5/45

5.5/30

4.5/40

4/55

2/30

2/25

6/50

8/65

6.5/40

5.5/80

5.5/50

6/40

7.5/85

7/70

10/90

10/45

10/60

10/30

10/45

8/40 10/32

10/80

10/605/35

3.5/40

6/35

5.5/55

5/45

4.5/65

3.5/25

6.5/70

6/60

NOTE: Settings are approximate. Adjust as required.

“−−−” Means not recommended.

“*” Thicker materials can be welded using proper technique,

joint preparation and multiple passes.

IMPORTANT: Match drive roll groove to diameter of wire being used.

Set Tension knob setting to 3 at start. Adjust tension

per instructions in the manual.

232 016-A

To disable wire speed tracking, proceed as follows:

1. Turn Power switch off.

2. Rotate Voltage knob to maximum.

3. Rotate Wire Speed knob to minimum.

4. Hold gun trigger in while turning on Power switch.

.To verify wire speed tracking is off, open drive roll pressure arm, pull trigger,

and rotate Voltage knob from min. to max. Drive roll speed will have minimal

change in rpm if tracking is off.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 32

5-7. Weld Parameter Chart For 230 VAC Model w/Factory Set

Non-Wire Speed Tracking Mode

.030” (0.8 mm)

.035” (0.9 mm)

1. Number on left of

slash is Voltage

Knob Setting.

(Example: 4.5 / 55)

2. Number on right

of slash is Wire

Speed Knob Setting.

(Example: 4.5 / 55)

.045” (1.2 mm) #000069 .035 − .045” (0.9 − 1.2 mm) #194012

.030 − .035” (0.8 − 0.9 mm) #194011

.024” (0.6 mm) #194010

.035” (0.9 mm) #000068

.030” (0.8 mm) #000067

.024” (0.6 mm) #087299

(DCEP)

(DCEN)

Refer to chart below to select Voltage and Wire Speed based on

thickness of material being welded.

Aluminum

Spool Gun

Aluminum

4043ER 100% Argon

(DCEP)

Stainless

Steel

Stain−

less

Steel

Selecting Wire, Gas and Control Settings for Aluminum

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 33

225 229-F

225 229−F

1.5/20 2/25

3.5/25

3/15

1/15

2.5/30

3.5/25

3.5/20

3/12

3.5/60

5/60

5.5/35

4/45

4/70 6/100

6/40

7/85

6/55

6/65

6.5/65

6.5/50

6.5/75

10/75

10/55

5.5/45

4.5/50

3.5/35

4.5/30

4.5/35

1.5/15 2/20 2/20 2.5/30 3.5/40 4.5/55 6/75 6/80 10/95

3/35

3.5/453.5/30 6/95

5/804.5/704/50

2/70 10/1008/955/704/702/70 10/908/905/654/602.5/65

3.5/283.5/25 7.5/956/855/705/604/45

2.5/20 7.5/806/654.5/50

4/40

3.5/25

2/12 2/15 2.5/20 4.5/45 6/55 6.5/60 10/703.5/303/25

4/40

4/25

4/20

2/20

1/10 4/35 6/55 7/60 10/653/25

2/15

3/452/25

NOTE: Settings are approximate. Adjust as required.

“−−−” Means not recommended.

IMPORTANT: Match drive roll groove to diameter of wire being used. Set Tension

knob setting to 3 at start. Adjust tension per instructions in the manual.

.045” (1.2 mm) #202926

.024” (0.6 mm) #220179

.030” (0.8 mm) #220179 #202926

.035” (0.9 mm) #220179 #202926

4/25 6/35 7/40 10/453/152.5/10

Thicker materials can be welded using proper technique,

joint preparation and multiple passes.

with optional Spool Gun, Order part no. 300371

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 34

5-8. Weld Parameter Chart For 230 VAC Model w/Wire Speed Tracking Mode

1. Number on left of

slash is Voltage

Knob Setting.

(Example: 4.5 / 65)

2. Number on right

of slash is Wire

Speed Knob Setting.

(Example: 4.5 / 65)

.045” (1.2 mm) #000069 .035 − .045” (0.9 − 1.2 mm) #194012

.035 − .045” (0.9 − 1.2 mm) #194012

.030 − .035” (0.8 − 0.9 mm) #194011

.024” (0.6 mm) #194010

.035” (0.9 mm) #000068

.030” (0.8 mm) #000067

.024” (0.6 mm) #087299

(DCEP)

(DCEN)

(DCEP)

Refer to chart below to select Voltage and Wire Speed based on

thickness of material being welded.

To enable wire speed tracking, proceed as follows:

1. Turn Power switch off.

2. Rotate Voltage knob to minimum.

3. Rotate Wire Speed knob to maximum.

4. Hold gun trigger in while turning on Power switch.

.To verify wire speed tracking is on, open drive roll pressure arm, pull trigger,

and rotate Voltage knob from min. to max. Drive roll speed will change rpm

if tracking is on.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 35

232 017-A

2.5/10

2/22

2.5/15

3/20

2.5/28

2.5/15

3.5/20

3.5/10

3.5/30

1/15

3/30

3.5/20

3.5/25

4/10

4/40

4/20

4/25

4/10

3.5/15

4.5/40

4/50

5/50

5/25

4/40

4/35

4/20

4.5/70

4.5/35

5.5/60

7/100

6/50

6/25

6/45

6/30

5.5/65

6.5/40

5.5/50

6.5/55

7.5/50

6.5/55

6.5/30

5.5/60

10/50

6.5/70

6/35

7/60

10/40

10/20

10/45

10/60

6/85

5/50

5.5/55

5.5/35

5/70

4.5/45

5/40

4.5/30

4.5/40

5/65

3/15

3/20

3/30

5/20

5/25

4/30

4.5/40

4/35

5/45

4/25

4/40

4.5/20

4/18

2/20

2/10

3.5/452.5/28

NOTE: Settings are approximate. Adjust as required.

“−−−” Means not recommended.

“*” Thicker materials can be welded using proper technique,

joint preparation and multiple passes.

IMPORTANT: Match drive roll groove to diameter of wire being used. Set Tension

knob setting to 3 at start. Adjust tension per instructions in the manual.

.045” (1.2 mm) #202926

.024” (0.6 mm) #220179

.030” (0.8 mm) #220179 #202926

.035” (0.9 mm) #220179 #202926

To disable wire speed tracking, proceed as follows:

1. Turn Power switch off.

2. Rotate Voltage knob to maximum.

3. Rotate Wire Speed knob to minimum.

4. Hold gun trigger in while turning on Power switch.

.To verify wire speed tracking is off, open drive roll pressure arm, pull trigger,

and rotate Voltage knob from min. to max. Drive roll speed will have minimal

change in rpm if tracking is off.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 36

SECTION 6 − MAINTENANCE &TROUBLESHOOTING

6-1. Routine Maintenance

YDisconnect power

before maintaining. .Maintain more often

during severe conditions.

n = Check Z = Change ~ = Clean l = Replace

* To be done by Factory Authorized Service Agent Reference

Every

Months

l Unreadable Labels ~ Weld Terminals nl Weld Cables

Every

Months OR

~ Inside Unit

6-2. Overload Protection

802 441

1 Supplementary Protector CB1

CB1 protects unit from overload. If

CB1 opens, unit shuts down.

Reset supplementary protector.

6-3. Drive Motor Protection And Tip Saver/Short Circuit Protection

A. Drive Motor Protection

Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, cycle unit power

off and back on again.

B. Tip Saver/Short Circuit Protection

The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contact

tip is shorted to workpiece, the unit shuts down the welding output, but the fan continues to run. To resume operation,

release gun trigger to reset unit. If the contact tip has stuck to the workpiece, release gun trigger, turn off unit, and

remove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue operation.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 37

6-4. Changing Drive Roll Or Wire Inlet Guide

1 Inlet Wire Guide

Remove guide by pressing on

barbed area or cutting off one end

near housing and pulling it out of

hole. Push new guide into hole from

rear until it snaps in place.

2 Drive Roll

The drive roll consists of two differ-

ent 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).

3 Retaining Pin

To secure drive roll, locate open slot

and push drive roll completely over

retaining pin, then rotate drive roll

1/4 turn to closed slot.

802 984

.024 Groove.030/.035 Groove

Stamped .024 Stamped .030/.035

6-5. Replacing Gun Contact Tip

Ref. 802 399-A

YTurn Off power before

replacing contact tip.

1 Nozzle

2 Contact Tip

Cut off welding wire at contact tip.

Remove nozzle.

Remove contact tip and install new

contact tip. Reinstall nozzle.

Tools Needed:

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 38

6-6. Cleaning Or Replacing Gun Liner

Ref. ST-802 399-A

8 mm / 10 mm

YDisconnect gun from unit.

Tools Needed:

Lay gun cable out straight

before installing new liner.

Head Tube

8 mm

Remove liner.

Remove nozzle, contact tip,

adapter, gas diffuser, and wire

outlet guide.

Blow out gun casing.

To Reassemble Gun:

Install and tighten new liner.

Cut liner off 3/4 in (20 mm) (3/8 in

[9.5 mm] for aluminum) from head

tube.

Install adapter, contact tip, and

nozzle.

10 mm

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 39

6-7. Replacing Switch And/Or Head Tube

Ref. ST-800 795-C

Tools Needed:

19 mm

Remove handle

locking nut.

Slide handle.

Secure head

tube in vice.

Loosen jam nut.

Remove from vice

and turn head tube

out by hand.

Hand-tighten head tube into cable connector. Place head tube in vice and tighten until

nuts are tight.

Remove from vice. Reposition handle and install

switch housing. Secure with handle locking nut.

YTurn Off welding power source

/wire feeder and disconnect gun.

Remove switch housing. Install new switch and

connect leads (polarity is not important). Reas-

semble in reverse order. If replacing head tube,

continue to end of figure.

.A complete Parts List is available on-line at www.MillerWelds.com

OM-225 311 Page 40

6-8. Troubleshooting Table

Trouble Remedy

No weld output; wire does not feed; fan

does not run.

Secure power cord plug in receptacle (see Section 4-7 or 4-8).

does not run.

Replace building line fuse or reset circuit breaker if open.

Place Power switch in On position (see Section 5-2, 5-1, or 5-3).

Reset welding power source supplementary protector if open.

No weld output; wire does not feed; fan

motor continues to run. Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when

unit has cooled (see Section 6-3).

Secure gun trigger plug (see Section 4-1).

Release gun trigger and cycle unit power off and back on again.

No weld output; wire feeds. Connect work clamp to get good metal to metal contact.

Replace contact tip (see Section 6-5).

Check for proper polarity connections (see Section 4-5).

Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

Low weld output. Connect unit to proper input voltage or check for low line voltage.

Place Power switch in On position (see Section 5-2, 5-1, or 5-3).

Electrode wire feeding stops during

welding.

Straighten gun cable and/or replace damaged parts.

welding.

Adjust drive roll pressure (see Section 4-11).

Change to proper drive roll groove (see Section 6-4).

Readjust hub tension (see Section 4-10).

Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove.

Replace contact tip if blocked (see Section 6-5). Oversized tip may be required for some wires.

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 6-4 or Section 6-6).

Replace drive roll or pressure bearing if worn or slipping (see Section 6-4).

Secure gun trigger plug (see Section 4-1).

Check and clear any restrictions at drive assembly and liner (see Section 6-4 or Section 6-6).

Release gun trigger and allow gun and motor protection circuitry to reset.

Have nearest Factory Authorized Service Agent check drive motor.

OM-225 311 Page 41

Notes

OM-225 311 Page 42

SECTION 7 − ELECTRICAL DIAGRAM

Figure 7-1. Circuit Diagram

OM-225 311 Page 43

234 419-B

OM-225 311 Page 44

SECTION 8 − MIG WELDING (GMAW) GUIDELINES

8-1. Typical MIG Process Connections

YWeld current can damage

electronic parts in vehicles.

Disconnect both battery

cables before welding on a

vehicle. Place work clamp as

close to the weld as possible.

Wire Feeder/

Power Source

Workpiece

Gun

Regulator/

Flowmeter

Gas Hose

Shielding Gas

Work Clamp

light mig 5/967 / Ref. 802 982-A

OM-225 311 Page 45

8-2. Typical MIG Process Control Settings

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.

NOTE

1/8 or

.125 in

Material thickness determines weld

parameters. Convert Material

(.001 in = 1 ampere)

.125 in = 125 A

Select Wire Size

Wire Size Amperage Range

.030 in

.035 in

.023 in

40 − 145 A

50 − 180 A

30 − 90 A

.035 in

Select Wire Speed

Select Voltage

Wire Recommendation

.030 in

.035 in

.023 in

2 in per ampere

1.6 in per ampere

3.5 in per ampere

Wire Speed

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

3.5 x 125 A = 437 ipm

Set voltage midway between high/low voltage.

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

125 A based on 1/8 in

Thickness to

(Amperage)

material thickness

Size (Approx.)

Amperage (A)

ipm = inch per minute

Ref. 804 681-A

Voltage controls height and width of

weld bead.

Wire speed (amperage) controls weld penetration

(wire speed = burn-off rate)

OM-225 311 Page 46

8-3. Holding And Positioning Welding Gun

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.

NOTE

1 Hold Gun and Control Gun

Trigger

2 Workpiece

3 Work Clamp

4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)

5 Cradle Gun and Rest Hand on

Workpiece

90°90°

0°-15°

45°

GROOVE WELDS

FILLET WELDS

End View Of Work Angle Side View Of Gun Angle

0°-15°

S-0421-A

OM-225 311 Page 47

8-4. Conditions That Affect Weld Bead Shape

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.

NOTE

Short Normal Long

10°

GUN ANGLES AND WELD BEAD PROFILES

ELECTRODE EXTENSIONS (STICKOUT)

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Push

Perpendicular Drag

GUN TRAVEL SPEED

Slow Normal Fast

S-0634

OM-225 311 Page 48

8-5. Gun Movement During Welding

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.

NOTE

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side To Side

Movement Along Seam

3 Weave Patterns

Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

1 2

8-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

S-0053-A

8-7. Good Weld Bead Characteristics

1 Fine Spatter

2 Uniform Bead

3 Moderate Crater During

Welding

Weld a new bead or layer for each

1/8 in (3.2 mm) thickness in metals

being welded.

4 No Overlap

5 Good Penetration into Base

Metal

S-0052-B

OM-225 311 Page 49

8-8. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that

cool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Wrong polarity. Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 4-5.

8-9. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets

in weld metal.

S-0635

Possible Causes Corrective Actions

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Wrong polarity. Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 4-5.

OM-225 311 Page 50

8-10. Troubleshooting − Excessive Penetration

Good Penetration

Excessive Penetration − weld metal melting through base metal

and hanging underneath weld.

Excessive Penetration S-0639

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase travel speed.

Wrong polarity. Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 4-5.

8-11. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow

fusion between weld metal and

base metal.

Lack of Penetration Good Penetration S-0638

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

maintaining proper welding wire extension and arc characteristics.

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

Wrong polarity. Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 4-5.

8-12. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with

base metal or a preceeding weld bead.

S-0637

Possible Causes Corrective Actions

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before

welding.

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

Wrong polarity. Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 4-5.

OM-225 311 Page 51

8-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal

resulting in holes where no metal remains.

S-0640

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

Wrong polarity. Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 4-5.

8-14. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover

joint formed by base metal.

S-0641

Possible Causes Corrective Actions

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

8-15. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces

base metal to move.

Base metal moves

in the direction of

the weld bead. S-0642

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-225 311 Page 52

8-16. Common MIG Shielding Gases

This is a general chart for common gases and where they are used. Many different combinations (mixtures) of

shielding gases have been developed over the years. The most commonly used shielding gases are listed in the

following table.

Application

Gas Spray Arc Steel Short Circuiting Steel Short Circuiting

Stainless Steel

Short Circuiting

Aluminum

Argon All Positions

Argon + 25% CO2Flat & Horizontal1 Fillet All Positions All Positions2

CO2Flat & Horizontal1 Fillet All Positions

Tri-Mix3All Positions

1 Globular Transfer

2 Single Pass Welding Only

3 90% HE + 7-1/2% AR + 2-1/2% CO2

OM-225 311 Page 53

SECTION 9 − PARTS LIST

9-1. Recommended Spare Parts

Quanti

Description

Part

No.

Item

No.

169 715 NOZZLE, slip type .500 orf flush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦087 299 TIP, contact scr .023 wire x 1.125. . . . . . . . . . . . . . . . . . . . .

♦000 067 TIP, contact scr .030 wire x 1.125. . . . . . . . . . . . . . . . . . . . .

♦000 068 TIP, contact scr .035 wire x 1.125. . . . . . . . . . . . . . . . . . . . .

♦000 069 TIP, contact scr .045 wire x 1.125. . . . . . . . . . . . . . . . . . . . .

♦194 010 LINER, monocoil .023/.025 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦194 011 LINER, monocoil .030/.035 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦194 012 LINER, monocoil .035/.045 wire x 15ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 975 O-RING, .187 ID x .103CS rbr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦OPTIONAL

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

9-2. Optional Drive Rolls

For All Feed Head Assemblies

PART NO. WIRE DIAMETER INCHES (mm)

220 179 .024 (.6) and .030 − .035 (.8 and .9)

202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove)

9-3. Options

PART NO. DESCRIPTION REMARKS

770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg)

194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg)

195 605 M-10 Replacement Gun 10 ft length/.030-.035 wire size

.A complete Parts List is available on-line at www.MillerWelds.com

Notes

Warranty Questions?

Call

1-800-4-A-MILLER

for your local

Miller distributor.

miller_warr 2007−01

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.

Effective January 1, 2007

(Equipment with a serial number preface of “LH” or newer)

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

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to

its original retail purchaser that new Miller equipment sold after

the effective date of this limited warranty is free of defects in

material and workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to such

defects in material or workmanship. Miller must be notified in

writing within thirty (30) days of such defect or failure, at which

time Miller will provide instructions on the warranty claim

procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time

periods. All warranty time periods start on the delivery date of the

equipment to the original end-user purchaser, and not to exceed

one year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped to

an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Process Controllers

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

* Water Coolant Systems (Non-Integrated)

* Flowgauge and Flowmeter Regulators (No Labor)

* HF Units

* Grids

* Spot Welders

* Load Banks

* Arc Stud Power Sources & Arc Stud Guns

* Racks

* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered under True Blue

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)

* Bernard-Branded Mig Guns (No Labor)

* Weldcraft-Branded TIG Torches (No Labor)

* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls

* APT & SAF Model Plasma Cutting Torches

* Remote Controls

* Accessory (Kits)

* Replacement Parts (No labor)

* Spoolmate Spoolguns

* Canvas Covers

Miller’s True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays

or parts that fail due to normal wear. (Exception:

brushes, slip rings, and relays are covered on Bobcat,

Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others, such

as engines or trade accessories. These items are covered

by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,

improperly operated or misused based upon industry

standards, or equipment which has not had reasonable and

necessary maintenance, or equipment which has been

used for operation outside of the specifications for the

equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4)

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods at

customer’s risk and expense. Miller’s option of repair or

replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Miller authorized service facility as determined by

Miller. Therefore no compensation or reimbursement for

transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY

OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION

OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an

implied warranty lasts, or the exclusion of incidental, indirect,

special or consequential damages, so the above limitation or

exclusion may not apply to you. This warranty provides specific

legal rights, and other rights may be available, but may vary from

state to state.

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations and

exclusions set out above may not apply. This Limited Warranty

provides specific legal rights, and other rights may be available,

but may vary from province to province.

PRINTED IN USA  2007 Miller Electric Mfg. Co.2007−01

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

www.MillerWelds.com

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier to:

For Service

Owner’s Record

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims, contact

your distributor and/or equipment manufacturer’s

Transportation Department.

Contact your Distributor for:

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller

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