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Millermatic 211 Auto

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1. Notes Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way CZ Minier Effective January 1 2010 Equipment with a serial number preface of MA 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
2. blows dust and dirt from valve Close valve 3 Oylinder 4 Regulator Flowmeter d Install so face is vertical 5 Regulator Flowmeter Gas D ESERE EN Hose Connection 6 Welding Power Source Gas Hose Connection a Connect supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Flow rate should be set when gas is flowing through welding power source and welding gun Open feed head pressure assembly so Argon Gas Or that wire will not feed Press gun Mixed Gas trigger to start gas flow Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturers recommended flow rate After flow is set close feedhead pressure assembly Tools Needed 3 5 8 1 1 8 in Feedhead Pressure Assembly Open n Feedhead Pressure Assembly Closed Ref 802 028 805 389 A Ref 802 982 A Ref 243 861 A OM 239 988 Page 16 A complete Parts List is available on line at www MillerWelds com 4 7 Connecting 1 Phase Input Power For 230 VAC Input A Installation must meet all National and Local Codes have only qualified persons
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4. OM 239 988J 2010 10 m Processes err NER GMAW Welding Flux Cored FCAW Welding Description Arc Welding Power Source And Wire Feeder Millermatic 211 Auto Set w MVP OWNER S MANUAL Visit our website at File MIG GMAW www MillerWelds com m From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U 3 BI E PEENI 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 Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on yea
5. gt Use pressure indicator scale to set a desired drive roll pressure Begin with a setting of 3 4 If necessary make additional adjustments Tighten after trying this initial setting 6 ERI Q 1 Pressure le 2 Indicator b 1 Blo Scale No ON orr O INPUT POWER Ja N Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove Close and tighten pressure assembly and let go of wire 9 Tighten X Remove gun nozzle and contact tip Turn power on e D WOOD 2 Press gun trigger until wire comes Be sure that tip matches wire diameter pi erat out of gun Keep gun cable as Reinstall contact tip and nozzle igne Cui ie IS pping straight as possible Ref 802 982 A Ref 205 837 Ref 243 861 A OM 239 988 Page 22 A complete Parts List is available on line at www MillerWelds com 4 15 Removing MIG Gun From Welding Power Source RP v b Cut Off End Of Wire Open Pressure Assembly E Hold wire tightly to keep it from unraveling ES Rewind Wire Onto Spool Fasten Loosen Knob Disconnect Gun Trigger End Of Wire To Spool Plug And Pull
6. e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit 9 Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemi
7. ere SHUIN S SON c9 Q p ejdusexg i Bumes qouy 5 use s 9 JO YO uo JOQUINN m 99 6 7 ejdurex3 dwe aom f f Buas qouy peeds or mel 21M SI USBISJO os M 94102 104 9JIM PIIOS 104 ybu uo Jequanw O33qs am eponooj3lleAnisod epoaoo 3 N3iod daiod ALIHV10d 9NIDNVHO pee pee AM BAU 94M pepjo Bureq e1euu jo sseuxoiui uo peseq peeds pue 199 95 0 MOJeq HEYD oj dnjes jenuen 9b 01 BneB pz HOA OTE uu 60 S80 ww 0 080 ww 90 720 ww 6 0 SE0 ww 8 0 080 ww 90 720 siayaweig SazIS 911 09 ASZ AV 969 9H 9606 suoneoirpdde 100pino 10 Apulm 10 poo sen Buipjeius ON 09 96001 02 686 IW GL seo 113 08906 jo 9 6 Sese 9 5 pajsabbng 4390 pas sse ureis N39q LI LLZ3 239 992 C OM 239 988 Page 28 FF A complete Parts List is available on line at www MillerWelds com SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance x X E D x A Disconnect power Maintain more often x before maintaining during severe conditions 17 Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent Every i n 2 2 VA FA 3 ese Months Unreadable Labels Q
8. ruere kim rm eme m rer ice exi ee dln Re E EU Ee 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Symboles utilises e deren v erar eed ich ue aure e ter gu T Ree ete nter gal 5 2 2 Dangers relatifs au soudage larc 5 2 8 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 2 6 Informations relatives aux CEM 222222 9 SECTION 3 SPECIFICATIONS e e xr e en net net on ee dan ee dire E n n dee 11 3 1 Specifications i0 d tige ppt RISE 11 3 2 Duty Cycle And Overheating ssssisssssssssss ese 12 3 3 Volt Ampere CUrvVes vus es re te eos elei rore Spe on Md paida Ra e RR peie da mer 13 SECTION INSTALLATION oe rera rr xum TREE NER ote niet dees Se sn es 14 4 1 Installing Welding GUn sie RR ne E E AG d e ea ER RR Rr qn 14 4 2 Installing Work Clamp seeker RR em E Ra rechner ue eue e ce 14 4 9 Work Cable Routing Inside Unit ee RII nn 15 4 4 Process Polarty Table is 5e EON NICA DOR SAG Gy hea 15 4 5
9. 030 035 Groove Stamped 024 N 024 Groove Stamped 030 035 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 14 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 OM 239 988 Page 30 A complete Parts List is available on line at www MillerWelds com 6 5 Troubleshooting Table Trouble Remedy No weld output wire does not feed fan does not run Secure power cord plug in receptacle see Section 4 12 Replace building line fuse or reset circuit breaker if open Place Power switch in On position see Section 5 2 Reset welding power source supplementary protector if open see Section 6 2 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 3 2 Secure gun trigger plug
10. 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 only to include SCRs diodes and discrete rectifier modules 2 3 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer Inverter Power Sources Unless Otherwise Stated Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Smith 30 Series Flowgauge and Flowmeter Regulators No Labor Transformer Rectifier Power Sources Water Coolant Systems Integrated 3 2 Years Parts Auto Darkening Helmet Lenses No Labor 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices CoolBelt and CoolBand Blower Unit No Labor External Monitoring Equipment and Sensors Field Options NOTE Field options are covered for the remaining warranty period of the prod
11. Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect ImplantedMedical Devices 9 Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and
12. cc cece cece eee eee nn n nnn 29 6 1 Routine Maintenance sere rer RE E EG he e a eR eae Ree n 29 6 2 Overload Protections sc vache dere ep roe rece etre lub 29 6 3 Drive Motor Protection And Tip Saver Short Circuit Protection 29 6 4 Changing Drive Roll Or Wire Inlet Guide eee 30 6 5 Troubleshooting Table 2 22 31 SECTION 7 ELECTRICAL DIAGRAM 4 4 ss hh huh 32 TABLE OF CONTENTS SECTION 8 MIG WELDING GMAW GUIDELINES 00 0 cece cece eee IIR nne 34 8 1 Typical MIG Process Connections 34 8 2 Typical MIG Process Control Settings 35 8 3 Holding And Positioning Welding Gun 36 8 4 Conditions That Affect Weld Bead Shape 37 8 5 Gun Movement During Welding 38 8 6 Poor Weld Bead Characteristics 38 8 7 Good Weld Bead Characteristics 2 38 8 8 Troubleshooting Excessive Spatter 39 8 9 Troubleshooting Porosily 444
13. e Lire et appliquer les instructions sur les B tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section N utiliser que les pi ces de rechange recommand es par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux DES RAYONNEMENT HAUTE FREQUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e
14. rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endom mag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres c
15. 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 gun Owner s Manual 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 Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts Adjust drive roll pressure see Section 4 14 Change to proper drive roll groove see Section 6 4 Readjust hub tension see Section 4 13 Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove Replace contact tip if blocked see gun Owner s Manual 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 gun Owner s Manual 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 gun Owner s Manual Release gun trigger and allow gun and motor protection circuitry to reset Have nearest Factory Authorized Service Agen
16. L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements P P OM Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s
17. arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories 9 Use equipment
18. base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconnait qu ils provoquent 239 988 Page 8 des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisation Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site internet www global ins com National Electrical Code NFPA Standard 70 d
19. cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N tiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tou
20. dees REX ee xem ene p eden E Rex ss 39 8 10 Troubleshooting Excessive Penetration 39 8 11 Troubleshooting Lack Of Penetration n 40 8 12 Troubleshooting Incomplete Fusion 42222 40 8 13 Troubleshooting 40 8 14 Troubleshooting Waviness Of Bead 41 8 15 Troubleshooting Distortion si rer e i II 41 8 16 Common MIG Shielding Gases 42 8 17 Troubleshooting Guide For Semiautomatic Welding Equipment 42 SECTION 9 PAHTS LIST due seed EVE seen ease Ses ene EE xn 44 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2010 03 A Protect yourself and others from injury read and follow these precautions 1 A A 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in th
21. 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 8 10 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneath weld Excessive Penetration Good Penetration S 0639 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed OM 239 988 Page 39 8 11 Troubleshooting Lack Of Penetration Lack of Penetration Lack Of Penetration shallow fusion between weld metal and T m A base metal Good Penetration S 0638 Possible Causes Corrective Actions Improper joint preparation Material too thick Joint prepara
22. les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtran
23. 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 OM 239 988 Page 40 8 14 Troubleshooting Waviness Of Bead EE 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 i 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 239 988 Page 41 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
24. of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Followthe guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment nn LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle id 9 Reduce current or reduce duty cycle before Ma starting to weld again e Do not block or filter airflow to unit N FLYING SPARKS can injure 9 Wear a face shield to protect eyes and face 4 e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards P e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards Les N MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire 4 9 r MOVING PARTS can injure e Kee
25. shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel Aluminum Argon X Argon 25 CO2 X 80 or greater Argon X x balance CO or Oxygen 100 CO X Tri Mix X 1 Limited short circuiting use 2 90 HE 7 1 2 AR 2 1 2 002 8 17 Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates but wire does not feed Too little pressure on wire feed rolls Increase pressure setting on wire feed rolls Incorrect wire feed rolls Check size stamped on wire feed rolls replace to match wire size and type if necessary Wire spool brake pressure too high Decrease brake pressure on wire spool Restriction in the gun and or assembly Check and replace cable gun and contact tip if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire feed rolls Incorrect cable liner or gun contact tip size Check size of contact tip and check cable liner length and diameter replace if necessary Gun end not inserted into drive housing properly Loosen gun securing bolt in drive housing and push gun end into housing just enough so it does not touch wire feed rolls Dirty or damag
26. terminal FCAW Self shielding wire DCEN Straight Polarity Connect to negative Connect to positive output no shielding gas output terminal terminal 4 5 Changing Polarity just hand tighten hardware A loose electrical connection will cause gt ear E Connection hardware must be tightened with proper tools Do not poor weld performance and excessive heating at the terminal block CHANGING POLARITY DCEP DCEN Electrode Positive Electrode Negative FOR SOLID WIRE Flux Core Wire 1 Lead Connections For Direct Current Electrode Positive DCEP 2 Lead Connections For Direct Current Electrode Negative DCEN Always read and follow wire manufacturers recommended polarity and see Section 4 4 Close door Ref 203 501 Ref 802 982 OM 239 988 Page 15 A complete Parts List is available on line at www MillerWelds com 4 6 Installing Gas Supply Obtain gas cylinder and chain to E running gear wall or other stationary support so cylinder cannot fall and break off valve DO NOT use Argon Mixed gas regulator flowmeter 1 Cap with CO shielding gas See Parts List for optional 2 Cylinder Valve CO gas regulator flowmeter and hose 1 ad Remove cap stand to side of valve 7 and open valve slightly Gas flow
27. www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Do not weld whilst carrying the welding power source or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2010 03 A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si o
28. 0 DUTY CYCLE 30 duty cycle at 150 amps 60 Hz 3 Minutes Welding 7 Minutes Resting Overheating AorV y p i OR Reduce Duty Cycle Minutes duty1 4 95 284 313 A OM 239 988 Page 12 3 3 Volt Ampere Curves FF A complete Parts List is available on line at www MillerWelds com A 120 VAC Input 30 25 20 VOLTAGE 10 16 1 M l 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 AMPERAGE MAX MIN 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 B 230 VAC Input 35 30 25 20 VOLTAGE 15 MAX MIN 10 90 110 130 AMPERAGE 150 170 190 210 230 240 580 A OM 239 988 Page 13 4 1 A complete Parts List is available on line at www MillerWelds com SECTION 4 INSTALLATION Installing Welding Gun Pa RP Correct Incorrect R 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob Insert end of gun throug
29. 7 Good Weld Bead Characteristics Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 239 988 Page 38 8 8 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead e Se 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 Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 8 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal LAE m Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding
30. A Follow electrical service guide for collar is completely tight x 230 VAC in Section 4 8 Do not use 3 Receptacle NEMA Type 5 15R plug rating to size branch circuit Customer Supplied protection Connect plug to receptacle OM 239 988 Page 19 A complete Parts List is available on line at www MillerWelds com 4 12 Selecting A Location And Connecting Input Power vg E 4 Pw as Q ef 18 in 457 mm of space for airflow A Do not move or operate unit where it could tip 805 390 C A Do Not cut off power cord connec For 120 volts AC input power a 20 ampere 5 Receptacle NEMA Type 5 20R tor and rewire The power cord con individual branch circuit protected by Customer Supplied nector and plugs will work with ML pon ic jos iS 6 Plug NEMA Type 6 50P standard NEMA receptacles Modi Ps VOIS POWET SES 7 Receptacle NEMA Type 6 50R fying power cord connector and plugs will void product warranty 1 Power Cord Connector Plug NEMA Type 5 15P Customer Supplied Select plug for power supply receptacle available at site Install plug onto power cord adapter As threaded collar is Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Receptacle NEMA Type 5 15R Customer Supplied Plug NEMA Type 5 20P Optional tightene
31. Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ins com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access
32. Changing Polanty e tr Y EUR ER VOIR RR Y GP P Pao qued 15 4 6 Installing Gas Supply gu RR RR ERR ERR REPE RO RERO ERR pondre dense 16 4 7 Connecting 1 Phase Input Power For 230 VAC Input 17 4 8 Electrical Service Guide For 230 VAC Input 18 4 9 Extension Cord Dat c i osse b wibiveda Re Pec disent sheet media 18 4 10 Serial Number And Rating Label Location 222 19 4 11 Multi Voltage Plug MVP Connection 19 4 12 Selecting A Location And Connecting Input Power 2 20 4 13 Installing Wire Spool And Adjusting Hub Tension 21 4 14 Threading Welding Wire 00 RIAM Ah 22 4 15 Removing MIG Gun From Welding Power Source 23 4 16 Connecting Spool Gun To Millermatic 211 2 24 4 17 Cable Management Strap ssnipe E E p A a E a E ha 25 SECTION 5 OPERATION eee edad eee oats NUN a a ME ae 26 Dell GOnlttols s naur Anne LA A T a E AET E E AT Hd TEE 26 5 2 Power SWIICH a PPP 27 5 8 WeldiParameter Chart nee nep YE Ede ee 28 SECTION 6 MAINTENANCE amp TROUBLESHOOTING
33. 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 OX OX In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2010 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was d
34. Gun From Unit Ref 802 982 A Ref 243 861 A OM 239 988 Page 23 A complete Parts List is available on line at www MillerWelds com 4 16 Connecting Spool Gun To Millermatic 211 RP 6 Incorrect Gun Not Seated Exposed O rings Correct will cause shielding Gun Fully Seated gas leakage 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 Polarity Changeover Terminal Block To make proper polarity connection see Section 4 5 7 MIG Gun Spool Gun Switch Place switch in Spool Gun position Close door Ref 804 984 A Ref 805 390 A Ref 801 987 OM 239 988 Page 24 FF A complete Parts List is available on line at www MillerWelds com 4 17 Cable Management Strap 9 1 Cable Management Strap Pu 7 1 Coil power cable and work cable and secure to unit using the cable management strap 805 392 B OM 239 988 Page 25 A complete Parts List is available on line at www MillerWelds com SECTION 5 OPERA
35. Indique des instructions sp cifiques A cal Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger dans l ordre indiqu 1 un poste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les
36. Set Amperes Input at Rated Welding Amperage Maximum Open Rated Load Output Weight Overall Output Range Circuit Voltage 230 V 60 Hz KVA KW W Gun Dimensions DC Single Phase Length 17 1 2 in 444 mm 150 A 23 5 Volts ERN DC 3096 Duty Cycle 30 210 34 24 3 5 5 4 75 Ca ee 5 8 in At 60 Hz Input 273 mm Height 15 3 4 in 400 mm Solid Flux Cored r 2 Wire Feed Speed Range Wire Type Stainless And Dia 024 035 in 030 045 in 80 565 IPM 2 0 14 4 m min At No Load 0 6 0 9 mm 0 8 1 2 mm 60 440 IPM 1 5 11 2 m min Feeding Wire OM 239 988 Page 11 A complete Parts List is available on line at www MillerWelds com 3 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating 150 If unit overheats thermostat s A 120 VAC 125 opens output stops and cooling Input 368 fan runs Wait fifteen minutes for unit to cool Reduce amperage or 1 duty cycle before welding n NOTICE Exceeding duty cycle can damage unit and void warranty lt A 50 Lui 37 5 25 0 10 15 20 25 30 40 50 60 70 80 90 100 7 DUTY CYCLE 2096 duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting B 230 VAC Input 500 450 400 350 300 1 250 ne n 200 150 a uj 100 50 10 15 20 30 40 50 60 70 809010
37. Size Max Cord Length 120V 1 60 14 ANG 27 ft 8 m 230 V 1 60 14 AWG 53 ft 16 m OM 239 988 Page 18 FF A complete Parts List is available on line at www MillerWelds com 4 10 Serial Number And Rating Label Location The serial number and rating information for this product is located on back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 4 11 Multi Voltage Plug MVP Connection Selecting Plug 2 m nector and rewire The power cord connector and plugs will work with standard NEMA re ceptacles Modifying power cord connector and plugs will 6 void product warranty A Do not cut off power cord con int Connecting Plug To Power Cord gt 0 0 MVP Plug1 2010 10 Ref 805 390 C Selecting Plug 4 Plug NEMA Type 5 20P Optional Connecting Plug To Power Cord 1 Power Cord Connector From 5 Receptacle NEMA Type 5 20R Welding Power Source Customer Supplied Align arrow on plug with arrow on power 6 Plug NEMA Type 6 50P cord connector Push together Select plug for power supply receptacle 7 Receptacle NEMA Type 6 50R available at site Not all plugs shown are Customer Supplied Tighten threaded collar As threaded collar provided as standard with unit 8 l is tightened push plug onto adapter until
38. TION Controls 5 1 T ES A 120 230V Wire Welder 120 Volt 24 gauge to 3 16 230 Volt 24 gauge to 3 8 Welds 24 gauge to 3 8 Mild Steel dE F0354 Auto Set 2 WELD WIRE DIAMETER 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 3 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 3 3 MIG Gun Spool Gun Switch Switch allows selecting either a MIG gun or a spool gun depending on the type of gun connected to the unit 4 Over Temperature Light If unit overheats light flashes and output stops Allow unit to cool before resuming operation 5 Gun Trigger Receptacle 6 Auto Sef Light To use Auto Set mode rotate Wire Speed control inside blue green area for the applicable Weld Wire Diameter Ref 239 991 B Auto Sef 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 3 Rotate Voltage control inside blue green scale 24 ga to 3 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 Di
39. Weld Terminals Weld Cables Every 6 Months Q Inside Unit 6 2 Overload Protection N 1 Supplementary Protector CB1 D The power switch also functions as supplementary protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset power switch supplementary protector 805 389 A 6 3 Drive Motor Protection And Tip Saver Short Circuit Protection A Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative cycle unit power off and back on again B Tip Saver Short Circuit Protection The tip saver short circuit protection extends contact tip life and protects internal components from damage If contact tip is shorted to workpiece the unit shuts down the welding output but the fan continues to run To resume operation release gun trigger to reset unit If the contact tip has stuck to the workpiece release gun trigger turn off unit and remove contact tip from workpiece Check contact tip and replace if damaged Turn on unit to continue operation OM 239 988 Page 29 A complete Parts List is available on line at www MillerWelds com 6 4 Changing Drive Roll Or Wire Inlet Guide
40. alling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional 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 Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in Indicates special instructions TK This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below fo
41. ameter see Section 5 3 Blue shaded areas are for 035 wire applications Green shaded areas are for 030 wire applications OM 239 988 Page 26 5 2 Power Switch A complete Parts List is available on line at www MillerWelds com Pa ous A ANE SN 8 5 8 GC gt gt C gt C D ER C o CSD CD 65 CD 2 o gt gt amp gt C 2 gt C gt Power Switch The power switch also functions as supplementary protector CB1 see 805 389 A OM 239 988 Page 27 FF A complete Parts List is available on line at www MillerWelds com Weld Parameter Chart 5 3 LOp6L LIUUZ L 6 0 S70 SE0 Y690000 utuZ L Sp0 Y ZV0v6Ls unuz 1 6 0 570 5 0 890000 W6 0 S 0 6LLOZe ww g 0 oco LLov61 w6 0 8 0 620 0 0 2900002 u19 0 0 0 6LLOZz ww 9 0 pz0 nl o1op6L uno vzo 6ozzg0s uw9 0 vzo 9c6c0z2it 926207 926207 6LLOZZ ww 60 Seo 912691 9 UIOOWSM siejeuriq SIM sieun SdIL 1981100 sjjou nna pe oo15 ena auey yono S8 01 SZ Z 9 9 S9 S S S9 v i 02 01 OZ S
42. 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
43. d push plug onto adapter until collar is completely tight Connect plug to receptacle OM 239 988 Page 20 A complete Parts List is available on line at www MillerWelds com 4 13 Installing Wire Spool And Adjusting Hub Tension Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set G NU Installing 8 in 203 mm Wire Spool Adapter used with 8 in 203 mm spool only When a slight force is neededto turn spool ten sion is set Align locking hole in spool with locking pin on spool hub Retaining ring used with 8 in 203 mm spool only Tools Needed Cc UB Lc E S irik 803 012 803 013 B Ref 802 444 C OM 239 988 Page 21 A complete Parts List is available on line at www MillerWelds com 4 14 Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight X O1 250 Tools Needed 1 Hold wire tightly to keep it 3 from unraveling o R L3 N 102 mm Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire
44. e National Fire Protec tion Association Quincy MA 02269 t l phone 800 344 3555 site Internet www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada LAW 5NS t l phone 800 463 6727 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en l
45. e causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s CIS gt e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 239 988 Page 7 3 4 3 Les PIECES MOBILES peuvent causer des blessures Ne pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage Les PIECES MOBILES peuvent causer des blessures e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua lifi Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS
46. e text NOTICE Indicates statements not related to personal injury 1 4 4 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of f
47. eate an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source 60 Hz Single Phase Input Voltage V 230 Input Amperes A At Rated Output 24 3 Max Recommended Standard Fuse Rating In Amperes Time Delay Fuses 25 Normal Operating Fuses 35 Min Input Conductor Size In AWG 4 14 Max Recommended Input Conductor Length In Feet Meters ds Min Grounding Conductor Size In AWG 4 14 Reference 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps 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 4 9 Extension Cord Data When calculating max cord length remember to include conductor length from line disconnect device to input power receptacle Input Power Input Voltage Phase Hertz Conductor
48. ed kinked liner Replace liner Wire feeds but no gas flows Gas cylinder empty Replace empty gas cylinder Gas nozzle plugged Clean or replace gas nozzle Gas cylinder valve not open or flowmeter not adjusted Open gas valve at cylinder and adjust flow rate Restriction in gas line Check gas hose between flowmeter and wire feeder and gas hose in gun and cable assembly Loose or broken wires to gas solenoid Have Factory Authorized Service Agent repair wiring Gas solenoid valve not operating Have Factory Authorized Service Agent replace gas solenoid valve Incorrect primary voltage connected to welding power source Check primary voltage and relink welding power source for correct voltage OM 239 988 Page 42 Problem Probable Cause Remedy Welding arc not stable Wire slipping in drive rolls Adjust pressure setting on wire feed rolls Replace worn drive rolls if necessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameters Loose connections at the gun weld cable or work cable Check and tighten all connections Gun in poor shape or loose connection inside gun Repair or replace gun as necessary OM 239 988 Page 43 SECTION 9 PARTS LIST 9 1 Recomm
49. elivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department ORIGINAL INSTRUCTIONS PRINTED IN USA 2010 Miller Electric Mfg Co 2010 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 amp Canada FAX 920 735 4134 International FAX 920 735 4125 For International Locations Visit www MillerWelds com C Miller
50. ended Spare Parts Item Part No No Description Quantity 246 372 NOZZLE slip type 500 orf flush 1 087 299 TIP contact scr 023 wire x 1 125 UTE E rre 000 067 TIP contact scr 030 wire x 1 125 Pair eA 000 068 TIP contact scr 035 wire x 1 125 m 000 069 TIP contact scr 045 wire x 1 125 EUN 194010 LINER monocoil 023 025 wire x 15 consisting of 1 ree PLA eret 194011 LINER monocoil 030 035 wire x 15ft consisting of 1 E 194012 LINER monocoil 035 045 wire x 15ft consisting of 1 PE N ue e 079975 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 248 282 M 100 Replacement Gun 10 ft length 030 035 wire size A complete Parts List is available on line at www MillerWelds com OM 239 988 Page 44 Notes
51. erence ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment Be sure this welding machine is installed and grounded according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 239 988 Page 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling A This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 1 5 Principal Safety Standards Safety in Welding Cutting and
52. es attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 t l phone 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 Quincy MA 02269 9101 t l phone 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 Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux let l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 t l hone 1 800 232 4636 site internet www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circu
53. h opening in front panel until it bottoms against drive assembly Tighten knob 4 Gun Trigger Plug Insert into receptacle and tighten threaded collar Close door ef 802 982 A Ref 243 861 A Ref 801 987 4 2 Installing Work Clamp RP Tools Needed 7 16 in 1 7 16 in E Tighten connection hardware with proper tools Do not just hand tighten hardware A loose electrical connection will cause poor weld performance and ex cessive heating of the work clamp Work Clamp Work Cable From Unit Screw Flat Washer Lock Washer Nut Route work cable through hole in clamp handle Secure cable with hardware as shown O1 wn 805 460 OM 239 988 Page 14 A complete Parts List is available on line at www MillerWelds com 4 3 Work Cable Routing Inside Unit CP t0 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 Ref 802 982 A 4 4 Process Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW Solid wire with shield DCEP Reverse polarity Connect to positive 4 out Connect to negative output ing gas put terminal
54. ircuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille 9 Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appa
55. ists in inverter weld ing power sources AFTER removal of inputpower 9 Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health OM 239 988 Page 1 Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work 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 Do 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 ga
56. it de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 239 988 Page 9 OM 239 988 Page 10 A complete Parts List is available on line at www MillerWelds com SECTION 3 SPECIFICATIONS 3 1 Specifications A 120 VAC w Auto Set Maximum Amperes Input at Rated Welding DANS Rated Load Out Weight Overall Output Amperage Range Open Circuit put 120 V 60 Hz KVA KW W Gun Dimensions Voltage DC Single Phase Length 17 1 2 in 444 mm 90 A 20 74 Ib sagan Volts DC 20 30 140 30 20 29 25 34 kg 5 8 in Duty Cycle 273 mm Height 15 3 4 in 400 mm Solid Stainless Flux Cored Wire Feed Speed Range Wire Type 4 in i And Dia E 6 d E Fico 030 035 in 80 565 IPM 2 0 14 4 m min At No Load paa 0 6 0 0 8 0 9 mm 60 440 IPM 1 5 11 2 m min Feeding Wire mm mm B 230 VAC w Auto
57. ithin 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use OM 239 988 Page 2 Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames
58. le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ues en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger A pu Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne passe servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants L
59. make this installation GND PE Earth Ground Disconnect and lockout tagout input power before connecting input conductors from unit Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal 1 Black And White Input Conductor L1 And L2 2 Green Or Green Yellow Grounding Conductor 3 Input Power Cord 4 Disconnect Device switch shown in the OFF position 5 Disconnect Device Grounding Terminal 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first NI Connect input conductors L1 and L2 to disconnect device line terminals IN 7 Over Current Protection L1 Select type and size of over current Ay protection using Section 4 8 fused disconnect switch shown 8 Receptacle NEMA 6 50R Customer Supplied Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 230 VAC 1 v Tools Needed B 803 766 B Ref 802 443 A OM 239 988 Page 17 A complete Parts List is available on line at www MillerWelds com 4 8 Electrical Service Guide For 230 VAC Input A Failure to follow these electrical service guide recommendations could cr
60. n l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit A Seul un personnel qualifi est autoris a installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir a distance toutes les personnes notamment les enfants de l appareil UNE DECHARGE ELECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est Sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil
61. ngle Side View of Gun Angle GROOVE WELDS e 0 15 is 45 7 N End View of Work Angle Side View of Gun Angle FILLET WELDS S 0421 A OM 239 988 Page 36 8 4 Conditions That Affect Weld Bead Shape L5 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 p 10 l l 0 7 3 Push b 4 10 l Leeeem ey uua i p Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long ELECTRODE EXTENSIONS STICKOUT le Le LE Short Normal Long FILLET WELD ELECTODE EXTENSIONS STICKOUT SS a y Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 239 988 Page 37 8 5 Gun Movement During Welding gt Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads works better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side To Side 1 2 Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode 3 RCC S 0054 A 8 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S 0053 A 8
62. p away from moving parts such as fans AJ e Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interf
63. r necessary actions to avoid the hazards disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual 9 Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE ex
64. reil en service Li LA CHUTE DE L EQUIPEMENT peut provoquer des blessures e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivreles consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication 94 110 lors du levage manuelle de pi ces ou quipements lourds N Jg B L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT P e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal MMC e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES PROJET ES peuvent provoquer des blessures y e Porter un cran facial pour prot ger le visage les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manoeuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent d
65. restrictions for passers by or individual risk assess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 239 988 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 48rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 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 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website
66. rs NII 0001 of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the AR d S exact part you may need to fix the problem the ISO 9001 Quality System Warranty and service information for your Standard particular model are also provided REGISTERED QUALITY SYSTEM 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 Mill mer Mil_Thank 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1515 Symbol USAGE vos ani da Lier nr dates ri mate den names ia dernier dt 1 1 2 Arc Welding Hazards zeste een ERU re ERE E ES eee et Ne 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 8 4 1 5 Principal Safety Standards 0 4 1 6
67. s Material thickness determines weld parameters US 1 8 or 0 125 in Convert Material Thickness to P Amperage A 0 001 in 1 ampere 0 125 in 125A Wire Size Amperage Range A k 0 023 in 30 90A m 0 030 in 40 145 A Select Wire Size 0 035 in 50 180A Wire Wire Speed Select Wire Speed Size Recommendation Approx Amperage 0 023 in 3 5 in per ampere 3 5 x 125 A 437 ipm 125 A based on 1 8 in 0 030 in 2 in per ampere 2 x 125 A 250 ipm material thickness 0 035 in 1 6 in per ampere 1 6 x 125 A 200 ipm ipm inches per minute Low voltage wire stubs into work High voltage arc is unstable spatter Select Voltage Set voltage midway between high low voltage Voltage controls height and Wire speed amperage controls weld width of weld bead penetration wire speed burn off rate OM 239 988 Page 35 8 3 Holding And Positioning Welding Gun L3 Welding wire is energized when gun trigger is pressed Before lowering helmet and pressing trigger be sure wire is no more than 1 2 in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 2 3 4 Electrode Extension Stickout PA 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 5 4 M 09 15 WA 90 90 End View of Work A
68. se en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES E XU SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a
69. ses Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Remove all flammables w
70. t REB yp VEL DEA REII o e t 5 gt e RED REZ gt D tI a T 7 RE3 4 34 S005 O 5 gt gt s RES amp REE 5 gt 2 lt TC PL ee REP XFMR REP 7 gt E gt J E eB gt gt a cl VOLTS AUTOSET DE gt REPE PLEPE RE I gt gt a lt p 22 RCE E gt D WFS 5 3 gt 3 I RCE4 REI B 22 3 gt 14 REI 4 gt gt RCe le gt ele 5 85 o o Ben SPOOLGUN gt RCI3 5 gt m I REI3 B gt gt E p PLGeB PLK POS NEG 249 839 A OM 239 988 Page 33 SECTION 8 MIG WELDING GMAW GUIDELINES 8 1 Typical MIG Process Connections A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Regulator Flowmeter i Wire Feeder Power Source Gun qo vu bsc ele 2 Gas 5 t Workpiece T LA Work Clamp Shielding Gas Ref 801 909 A OM 239 988 Page 34 8 2 Typical MIG Process Control Settings gt 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 specification
71. t check drive motor OM 239 988 Page 31 SECTION 7 ELECTRICAL DIAGRAM amp WARNING Do not touch live electrical parts S 9 Disconnect input power or stop engine before servicing 7 9 Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit POWER CORD ADAPTER CONFIGURATIONS WHT RED edav SDA O GRN RED BLK HSV 5 g uPp GRN RETI BLK ISA 5 5P GRN OM 239 988 Page 32 ELK lt CHI i lt WHT S I ae RED 5 lt O 9 0 URN MGRNZXELD Il IB BLK H gt 4 24 VAC Os RED 5 5 HT BLUES 13 PLGA RCEZ RCEU PLGA LED i32 THERMAL OVERLOAD i gt 134 AUTOSET LED 5 24 TRIGGER 2 gt 210 zog 138 mm 137 RES Figure 7 1 Circuit Diagram lt RE4 lt REIZ lt RCS REI AR RCI PLGI RCe PLGe R R C3 PLG3 CI3 PLG13 AN CIN a 1 i Lu RLI3 8 REI3 I RLI3 4 Ha a RCD 4 AAN IN WN A za RCe 10 VAN za LI3 B X RLI3 7 RCI gt g
72. t objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 239 988 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces LES PI CES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et
73. tion 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 Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 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 8 13 Troubleshooting Burn Through Burn Through weld metal
74. ts appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et 97 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 239 988 Page 6 LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s
75. uct they are installed in or for a minimum of one year whichever is greater Flowgauge and Flowmeter Regulators No Labor RFCS Foot Controls Except RFCS RJ45 Fume Extractors HF Units ICE Plasma Cutting Torches No Labor Induction Heating Power Sources Coolers and Electronic Controls Recorders Load Banks Motor Driven Guns w exception of Spoolmate Spoolguns PAPR Blower Unit No Labor Positioners and Controllers Racks Running Gear Trailers Spot Welders Subarc Wire Drive Assemblies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Work Stations Weld Tables No Labor 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor OX x F HF F 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered

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