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Millermatic 211

1. n D Disconnect power Maintain more often before maintaining during severe conditions y Check Change Clean x Replace Reference Kee To be done by Factory Authorized Service Agent a CA Every Du 2 3 Months Weld Terminals x Weld Cables Every 6 Months Inside Unit 7 2 Overload Protection 1 Supplementary Protector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector O 270 208 A 7 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 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 265 809 Page 31 E A complete Parts List is available on line at www MillerWelds com 7 4 Troubleshooting Table Trouble Remedy No weld output wire does not feed fan does not run
2. 5 5 Changing Polarity e Always read and follow wire En manufacturer s recommended polarity and see Section 5 4 Tools Needed 7 16 in Connection hardware must be tightened with proper tools Do not just hand tighten hardware A loose electrical connection will cause poor weld performance and excessive heating at the terminal block DCEP DCEN Electrode Positive Electrode Negative FOR SOLID WIRE FOR FLUX CORE WIRE ww JO H Ref 267 805 A Ref 267 825 A OM 265 809 Page 16 E A complete Parts List is available on line at www MillerWelds com 5 6 Installing Welding Gun Or Spool Gun 1 Drive Assembly 2 Gun Trigger Plug 3 Gun Trigger Receptacle Route gun trigger plug through front panel Insert plug into receptacle and tighten threaded collar 4 Gun Securing Knob 5 Gun End Loosen knob Insert end of gun through opening in front panel until it bottoms against drive assembly Tighten knob Close door gt Be sure that gun end is tight against drive assembly Incorrect installation will have adverse effects on gas flow Correct Incorrect Ref 267 805 A 267 807 A OM 265 809 Page 17 E A complete Parts List is available on line at www MillerWelds com 5 7 Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole Push new guide into hole fro
3. 2 Outside Handles 3 Middle Handle Lift or move the machine using both outside handles or middle handle Do not move or operate 18 in unit where it could tip iK 460 mm QG 271 714 A 5 2 Installing Work Clamp 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 Tools Needed 805 460 A OM 265 809 Page 14 gt A complete Parts List is available on line at www MillerWelds com 5 3 Work Cable Routing Inside Unit 1 Work Cable 2 Output Terminal Block Work cable is routed through the small hole in front panel and routed along base of unit to output terminal block Ref 267 805 A Notes OM 265 809 Page 15 gt A complete Parts List is available on line at www MillerWelds com 5 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 out Connect to negative output ing gas put terminal terminal FCAW Self shielding wire DCEN Straight Polarity Connect to negative Connect to positive output no shielding gas output terminal terminal
4. 265 381 A 1 Process Select Control 3 Auto Set LED 4 Voltage Material Thickness Control Turn control to select process material and type of shielding gas 2 Wire Speed Wire Diameter Control To turn Auto Set on turn the Wire Speed Wire Diameter control knob to the desired wire diameter setting The Auto Set light illuminates indicating Auto Set is on gt A blinking Auto Set LED indicates pa rameter is not recommended Adjust the Voltage Material Thickness control knob to the desired steel material thickness to weld gt There is no adjustment within the material thickness band 6 3 Jog Mode If gun trigger is held for longer than 3 seconds without initiating a weld arc unit will enter Jog mode and disable weld output e Jog mode is used to quickly feed wire through the wire drive assembly and MIG gun e While in Jog mode wire feed speed is adjustable using the Wire Speed Wire Diameter control knob e To exit Jog mode release gun trigger OM 265 809 Page 28 E A complete Parts List is available on line at www MillerWelds com Weld Parameter Chart 6 4 ex unuc 6 uuy 9 uwug y musel n8 91 EE Eu u papu uuuuoosai JOU SULAN paunbei se isnipy ayeuxoidde aie shulles JLON enuew ay ul suononnsul 19d uo sua jsnipy els Je z o1 Bunjas qouy UOISUAL 19s pasn Buraq al JO 19 9uIeIp 0 3A001J6 1194 3ALIP OORT d te EE 1109 SpJ949 111
5. OM 265 809 Page 42 Problem Probable Cause Remedy 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 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 265 809 Page 43 SECTION 10 PARTS LIST E A complete Parts List is available on line at www MillerWelds
6. Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at http www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs 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 ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association 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 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF The current from arc welding and allied pro cesses including spot welding gouging plasma arc cutting and induction heating operations
7. 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 9 13 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains S 0640 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady travel speed OM 265 809 Page 40 9 14 Troubleshooting Waviness Of Bead k 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 9 15 Troublesh
8. Visit our website at www MillerWelds com Q Miller OM 265 809A 2015 06 Processes MIG GMAW Welding Flux Cored FCAW Welding Description a 2 Es Arc Welding Power Source And Wire Feeder Millermatic 211 OWNER S MANUAL File MIG GMAW et 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 1 Y E BL E Her 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 Con ele CL he i every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick Leila a WO te and easy With Miller you can count on years Wl 0001 of reliable service with proper maintenance And if fo
9. 2 1 2 2 2 3 2 4 2 5 2 6 SYVMDOISS USES take an dr e II Dangers relatifs Au Soudage arc uuu u u u de D ENN NEEN e die oo die ax Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Proposition californienne 65 Avertissements Principales normes de SEGUI curra Ntormations relaves e EE SECTIONS DEFINITIONS Ein ee ti EA AA AAA eee ii E E 3 1 3 2 Additional Safety Symbols And Definitions Miscellaneous Symbols And Definitions SECTION SPECIFICATIONS up ar AAA AA E eek Rea eet ees 4 1 4 2 4 3 4 4 4 5 Serial Number And Rating Label Location 2 UIE SPCCHICAIONG lt u tev redada AAA AAA eh gee bad bens Environmental Specifications Duty Cycle And Overheating Volt Ampere ee SECTIONS INSTALLATION SE cinco tweeter AA EE decoration id rennes 5 1 5 2 5 3 5 4 95 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 5 14 5 15 selecting A LOCATON sus suis ads patie tas ntl ews kausa s wee os Rs Sens MET ees Rees Installing WOrK Clamp es 6245 i025 deteste cade tata test e tals Gets Gods wale che debat Work Gable Routing Inside Unit s u gek keeles ads Gite ies leas Gets tance Ghee dw Proces
10. 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 e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the welding process e lf AC output is required use remote output control if present on unit e 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 t
11. 4 sMOUDISSHOOUNG TADS ec Sect ge Lu L t ia ne conte wae Senta aie SECTION 8 ELECTRICAL DIAGRAM o occcoccc eee eee eee eee eee SECTION 9 GMAW WELDING MIG GUIDELINES SECTION 10 PARTS LIST or ce cutee ease tipi eee de RR Du SW ae see COMPLETE PARTS LIST Available at www MillerWelds com WARRANTY 31 31 31 31 32 34 36 44 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2013 09 Protect yourself and others from injury read follow and save these important safety precautions and operating instructions 1 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 the text NOTICE Indicates statements not related to personal injury 1 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
12. Agent Over Temperature light blinking four times Unit has experienced an over voltage condition Contact nearest Factory Authorized Service Agent Over Temperature light blinking five times Fan tach error Contact nearest Factory Authorized Service Agent Over Temperature light blinking six times Thermistor error Contact nearest Factory Authorized Service Agent OM 265 809 Page 32 Notes OM 265 809 Page 33 SECTION 8 ELECTRICAL DIAGRAM CONTROL BOARD BLK CBI WT S1 VLT RC 1 PLG 4 US Oe ROG RC 4 PLG 4 WHT WHT RC 5 PLO 5 oe RC 7 PLG 7 GRN GRN YEL RC 8 PLG 8 i RC14 RC 9 PLG 9 RC 10 PLG 10 lt 207 ge RC13 RC 1 PLG 42 lt RC24 L1 RC25 YEL BLK RC8 4 AN OVERTEMP LED RED lt RC8 1 BLU BLK CE RCB 5 AN AUTOSET LED RED Z lt RCB 2 GRN BLK RC8 6 AY POWER LED RED RcB 3 RC5 1 RC5 2 RC5 3 RC5 4 RC5 5 RC5 6 RC9 3 SECONDARY THERMISTOR DCH A O ee OO MM211 ONLY RC 2 PLG 2 RC4 4 PRIMARY THERMISTOR PRIMARY THERMOSTAT Figure 8 1 Circuit Diagram OM 265 809 Page 34 RC23 RC22 RC20 RC21 RC12 1 RGIZ 3 gt gt CH gt gt 12 lt 1 TRIGGER P 15 3 SPOOL GUN RCS RC1 5 DCH gt 454 SPOOL GUN RGIA Sli GS RC1 8 18 O RC10 2 gt gt BLK ro7 1 gt BLK RC7 2 gt RC7 3 gt RC7 4 Hl RC2 1 gt RC2 4 gt RC2
13. 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 ur Miller
14. Flat amp Horizontal CO gt a All Positions Fillet Helium All Positions2 Argon Helium All Positions2 Tri Mix4 All Positions Globular Transfer Heavy Thicknesses Single Pass Welding Only 90 HE 7 1 2 AR 2 1 2 CO Also for GMAW P All Positions 0O NNN 9 17 Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Wire feed motor operates but Too little pressure on wire feed rolls wire does not feed 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 Too much pressure on wire feed rolls wire feed rolls bird nesting 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 damaged kinked liner Replace liner
15. 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 Pour d terminer la bonne ventilation il est recommand de proc der un pr l vement pour la composition et la quantit de fum es et de gaz auxquels est expos le personnel e Si la ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les fiches de donn es de s curit et les instruc tions du fabricant concernant les adh sifs les rev tements les nettoyants les consommables les produits de refroidissement les d graisseurs les flux et les m taux 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 de
16. com 10 1 Recommended Spare Parts Item Part No No Description Quantity ee 246 372 NOZZLE slip type 500 orf flush Se ie bots NE A des 087 299 TIP contact scr 023 wire x 1 125 dee de db 000 067 TIP contact scr 030 wire x 1 125 al pido ea ASE mota Bae 000 068 TIP contact scr 035 wire x 1 125 Ee Ee Ee 000 069 TIP contact scr 045 wire x 1 125 siete naam eee cha eet 194010 LINER monocoil 023 025 wire x 15ft consisting of 1 is ee D asas 194 011 LINER monocoil 030 035 wire x 15ft consisting of 1 ENERE taiice 194 012 LINER monocoil 035 045 wire x 15ft consisting of 1 ia E E OAE 079 975 DERIN CE 107 IDX E TO aria arias H 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 10 2 Optional Drive Rolls For All Feed Head Assemblies PART NO WIRE DIAMETER INCHES mm 261 157 024 6 and 030 035 8 and 9 and 030 035 8 and 9 VK Groove 220 179 024 6 and 030 035 8 and 9 Standard 202 926 030 035 8 and 9 and 045 1 2 VK Groove Optional 10 3 Options PART NO DESCRIPTION REMARKS 249 040 M 150 Replacement Gun 12 ft length 030 035 8 and 9 wire size 249 041
17. not use worn damaged undersized or repaired cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e 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 e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal Disconnect cable for process not in use e Use GFCI protection when operating auxiliary equipment in damp or wet locations SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of input power e Turn Off inverter disconnect input power and discharge input Capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn e Do not touch hot parts bare handed f d f e Allow cooling period before working on equip ment e To h
18. shielding gas See Parts List for optional 2 Cylinder Val CO gas regulator flowmeter and hose ylinder Valve Remove cap stand to side of valve Tools Needed and open valve slightly Gas flow YT 5 8 1 1 8 in blows dust and dirt from valve 1 Close valve Z SR 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 2 5 Regulator Flowmeter Gas Hose Connection 3 6 Welding Power Source Gas Hose Connection Connect supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source Argon Gas Or 7 Flow Adjust Mixed Gas Flow rate should be set when gas is flowing through welding power source and welding gun Open feedhead pressure assembly so that wire will not feed Press gun trigger to start gas flow Typical flow rate is 30 to 35 cfh cubic feet per hour Check wire manufacturers recommended flow rate 8 CO Adapter Customer Supplied 9 O Ring Customer Supplied Install adapter with O ring between regulator flowmeter and CO CO Gas cylinder After flow is set close feedhead pressure assembly Feedhead Pressure Assembly Closed 270 208 A Ref 247 832 A Ref 267 807 A Ref 267 805 A OM 265 809 Page 20 E A complete Parts List is available on line at www MillerWelds com 5 10 Installing Wire Spool And Adjusting Hub Tension Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set I
19. state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller wart 2015 01 gt Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair 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 2015 Miller Electric Mfg Co 2015 01 Miller Electric Mfg Co
20. 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 9 10 Troubleshooting Excessive Penetration E E 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 265 809 Page 39 9 11 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration S 0638 Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics Improper weld technique Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed Incorrect polarity Check polarity required by welding wire and change to correct polarity at welding power source 9 12 Troubleshooting
21. 5 gt RC2 8 gt RC2 7 RC2 6 gt AA WARNING e Do not touch live electrical parts MISE EN GARDE Ne jamais toucher les pi ces lectriques sous tension e e Disconnect input power or stop Couper l alimentation ou arr ter le moteur avant engine before servicing de proc der l entretien de appareil Ne pas faire fonctionner sans les capots e Do not operate with covers removed H I lified 8 I DANGER 8 L installation l utilisation et la maintenance doivent ELECTRI e Have only qualified persons install tre effectu es par des personnes qualifi es sc ee D ELECTROCUTION See use or service this unit OM 265 809 Page 35 SECTION 9 GMAW WELDING MIG GUIDELINES 9 1 atl GMAW 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 Regulator close to the weld as possible Flowmeter Wire Feeder Power Source Shielding Gas Workpiece A Work Clamp GMAW1 2015 01 GMAW Only Ref 801 909 A 9 2 Typical GMAW 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 specifications Material thickness determines weld YES Convert Material arameters i ny rl p 1 8 or 0 125 in Thickness to Amperage A f 0 001
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23. E Earth Ground 7 4 240 VAC 1 Tools Needed e 4 input4 2012 05 271 714 A 803 766 C Ref 802 443 A OM 265 809 Page 24 E A complete Parts List is available on line at www MillerWelds com 5 14 Connecting 1 Phase Input Power For 240 VAC Continued A Installation must meet all National and Local Codes have only qualified per sons make this installation Disconnect and lockout tagout input power before connecting input con ductors from unit Follow established procedures regarding the installation and removal of lockout tagout devices Always connect green or green yellow conductorto supply grounding termi nal first and never to a line terminal NOTICE The Auto Line circuitry in this unit Notes automatically links the power source to the primary voltage being applied either 120 or 240 VAC See rating label on unit and check input volt age available at site 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Disconnect Device Grounding Terminal Disconnect Device Line Terminals Black And White Input Conductor L1 And L2 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to dis connect device line terminals 7 Over Current Protection Select type and size of over current protection using Section 5 11 fused disconne
24. HUTE DE L QUIPEMENT 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 assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement cables et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages dar du poste LES TINCELLES PROJET ES peuvent provoquer des blessures e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement a la meuleuse dot e de protecteurs Cette man uvre 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 de causer un incendie loigner toute sub stance i
25. M 150 Replacement Gun 15 ft length 030 035 8 and 9 wire size OM 264 423 Page 44 Notes DECIMAL EQUIVALENTS Bea e wz Be Se B e e Be 9 0 359 Oe Ze 9 9 B 99 E 9 0 ve 9 60 Bez 3 Be e Se OS Be e Se e Bez 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 ur Miller Effective January 1 2015 Equipment with a serial number preface of MF 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
26. SZ ULM jeyajew e g Burp am alm JWE OO 8 duuexz A IIA ca p ejduex3 Bum s qouy Be1 OA SI USEIS JO ya uo Jeun ot 08 ol Ga e G9 r ejdurexz Dumeas qouy paads aan S yse s jo 146 uo 19QUUNN 2 seb Bulpjalys pue edA jenajew ssa901d joajas uo paseg paads ali pue Bel oA Dos 0 44u ye Leu 0 19 94 dNlas TYNNVN ER WEISEN IW NIIWIT1V ELEN SIA P a al 3 03409 1331S DH N09 14315 MAR ES SERIES SIA DIA SIA se Bulpjelys pue ad l eusjeu ss9901d 198 9S EEN o papjam Buleq ejau Jo ssaumolul 267 705 A OM 265 809 Page 29 Ref 267 705 A soe soso som sz ons EC seme o soso ons oem sss Leederen eg mme 5 unup 9 wwug y uruiz g mug z mme up uw6 0 8 0 wwg o uruig p ue ug ch Lime uw ul uw6 0 80 uwug o SEEE EMT 439 0 02 yuejod n8 91 fp 69 6g ebozzz epz ous ep eho 6g eboz zz eb pz 9ZIS DIM ayey moja sadAy anm 21192 A sasey Guipjaiyg pajsaf ins E 1 M u lt pa sabins 9 E 0 abneb pz 0A OFZ gt A complete Parts List is available on line at www MillerWelds com Weld Parameters 6 5 OM 265 809 Page 30 E A complete Parts List is available on line at www MillerWelds com SECTION 7 MAINTENANCE amp TROUBLESHOOTING 7 1 Routine Maintenance
27. act 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 5 7 or gun Owner s Manual Replace drive roll or pressure bearing if worn or slipping see Section 5 7 Secure gun trigger plug see Section 5 6 Check and clear any restrictions at drive assembly and liner See Section 5 7 or gun Owner s Manual Release gun trigger and allow gun and motor protection circuitry to reset Have nearest Factory Authorized Service Agent check drive motor Over Temperature light is on steady Thermostat TP1 open overheating Allow fan to run with gun trigger off thermostat closes when unit has cooled see Section 4 4 Over Temperature light blinking one time Trigger error Release trigger and check MIG gun for shorted trigger connection Contact nearest Factory Authorized Service Agent Over Temperature light blinking two times Shorted output Unit has determined welding gun has shorted to workpiece and turned off output Release trigger and check that gun is not in contact with workpiece Contact nearest Factory Authorized Service Agent Over Temperature light blinking three times Motor error Check for birds nesting at wire spool and drive assembly Verify proper drive roll alignment and tension and that wire drive pressure assembly is closed Contact nearest Factory Authorized Service
28. all unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit a FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment 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 Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can injure e Wear a face shield to protect eyes and face 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 e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch point
29. andle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 265 809 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health 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 The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed If ventilation is poor wear an approved air supplied respirator Read and understand the Safety Data Sheets SDSs and the manufacturers instructions for adhesives coatings cleaners consumables coolants degreasers fluxes and metals 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 gases 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 a
30. 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 15 B 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 OM 265 809 Page 21 E A complete Parts List is available on line at www MillerWelds com 5 12 Multi Voltage Plug MVP Connection Selecting Plug A Do not cut off power cord con nector and rewire The power cord connector and plugs will work with standard NEMA re ceptacles Modifying power cord connector and plugs will void product warranty MVP Plug1 2010 10 Ref 803 812 C Selecting Plug 4 Plug NEMA Type 5 20P Optional Connecting Plug To Power Cord 1 Power Cord Connector From S 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 SEH S Seet SC SE SR Customer Supplied Tighten threaded collar As threaded collar is tightened pus
31. creates an EMF field around the welding circuit EMF fields may interfere with some medical implants e g pace makers Protective measures for persons wearing medical implants have to be taken For example restrict access for passers by or con duct individual risk assessment 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 265 809 Page 4 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 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 25 West 43rd 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 o
32. ct 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 input4 2012 05 803 766 C Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 265 809 Page 25 gt A complete Parts List is available on line at www MillerWelds com 5 15 Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight O OI WN A Tools Needed 2 Hold wire tightly to keep it from unraveling Open pressure assembly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire gt Use pressure indicator to set a desired drive roll pressure Begin with a setting of 2 If necessary make additional adjustments after trying this initial setting Pressure Indicator Be sure that wire is seated in proper drive roll groove Close and tighten pressure Remove gun nozzle and contact tip Turn power on assembly and let go of wire 9 Tighten WOOD Press gun trigger until wire comes out of gun Easdiwire techeck di I Keep gun cable as straight as possible Be sure that tip matches wire diameter C O sis Reinstall contact tip and nozzle Tighten knob enough to prevent slipping Unit will enter Jog mode after trigger is Cut
33. du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le cable 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 a la pi ce pour viter le contact avec tout objet m tallique OM 265 809 Page 5 e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage D brancher le c ble pour le proc d non utilis e Utiliser une protection diff rentielle lors de l utilisation d un qui pement auxiliaire dans des endroits humides ou mouill s Il reste une TENSION DC NON NEGLIGEABLE dans les sources de soudage onduleur UNE FOIS alimentation coup e 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 e Ne pas toucher aux pi ces chaudes utiliser les outils recommand s et porter des gants de sou dage et des v tements pais pour viter les br lu res ESA LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz
34. er 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 265 809 Page 9 SECTION 3 DEFINITIONS 3 1 Additional Safety Symbols And Definitions Some symbols are found only on CE products Warning Watch Out There are possible hazards as shown by the symbols Safe1 2012 05 Drive rolls can injure fingers Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away Safe95 2012 05 Become trained and read the instructions before working on the machine or welding 3 2 Miscellaneous Symbols And Definitions Some symbols are found only on CE products CA re MEN EE V ee II Primary Voltage Single Phase E Static Frequency Internal Protection X Duty Cycle Converter Transformer Rectifier Rated No Load Conventional Line Connection Gas Metal Arc Voltage OCV Load Voltage eet Welding GMAW Re OM 264 423 Page 10 E A complete Parts List is available on line at www MillerWelds com SECTION 4 SPECIFICATIONS 4 1 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 thi
35. f 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 www osha 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_2013 09 Pour carter les risques de blessure pour vous m me et pour autrui lire appliquer et ranger en lieu s r ces consignes relatives 2 aux pr cautions de s curit et au mode op ratoire 1 Symbole
36. 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 interference 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 265 809 Page 3 1 4 California Proposition 65 Warnings 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 1 5 Principal Safety Standards
37. fteen minutes for unit to cool Reduce amperage or 250 pr duty cycle before welding NOTICE Exceeding duty cycle om 200 can damage unit and void warranty O D Q 150 lt ke Se 100 120V 20A 50 f gt E 10 20 30 40 50 60 70 80 90 100 Duty Cycle 120V Input 20 duty cycle at 115 amps 100 duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting Continuous Welding 240V Input 40 duty cycle at 150 amps 100 duty cycle at 100 amps ec 7 4 Minutes Welding 6 Minutes Resting Continuous Welding Overheating ee ESO A o S sb Reduce Duty Cycle Minutes duty1 4 95 272 269 A OM 265 809 Page 12 gt A complete Parts List is available on line at www MillerWelds com 4 5 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown 120 240V MIN 120V MAX 25 50 75 100 125 150 175 200 225 Amperes 272 270 A OM 265 809 Page 13 E A complete Parts List is available on line at www MillerWelds com SECTION 5 INSTALLATION 5 1 Selecting A Location A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 1 Line Disconnect Device Locate unit near correct input power supply
38. ge lt Perpendicular GUN ANGLES AND WELD BEAD PROFILES d JE ie Short Normal Long Short Normal Long ELECTRODE EXTENSIONS STICKOUT FILLET WELD ELECTODE EXTENSIONS STICKOUT ES Eee Normal GUN TRAVEL SPEED OM 265 809 Page 37 9 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 Stringer Bead Steady Movement Along Seam Weave Bead Side To Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 9 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 9 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 265 809 Page 38 9 8 Troubleshooting Excessive Spatter A Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead 2622624242 _ bogie Possible Causes Corrective Actions Wire feed speed too hig
39. ged 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 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 compressed gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Do not stand in front of or behind the regulator when opening the 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 FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not inst
40. h 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 9 9 Troubleshooting Porosity ANA Porosity small cavities or holes resulting from gas pockets in weld metal DALA Soes Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clean dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or liner Workpiece dirty Remove all grease oil moisture rust paint coatings and dirt from work surface before welding Use a more highly deoxidizing
41. h plug onto adapter until Follow electrical service guide for nd 2 Plug NEMA Type 5 15P 240 VAC in Section 5 11 Do not use collar is completely tight 3 Receptacle NEMA Type 5 15R plug rating to size branch circuit Customer Supplied protection Connect plug to receptacle OM 265 809 Page 22 E A complete Parts List is available on line at www MillerWelds com 5 13 Connecting 120 Volt Input Power e A Installation must meet all rory National and Local Codes have only qualified persons make this installation A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 NOTICE The Auto Line circuitry in this unit automatically links the power source to the primary voltage being applied either 120 or 240 VAC See rating label on unit and check input voltage available at site For 120 volts AC input power a 15 or 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required 1 Multi Voltage Plug And Power Cord Connector NEMA Type 5 15P Plug Shown For multi voltage plug connections see Section 5 12 2 Receptacle NEMA Type 5 15R Customer Supplied Input6 2011 03 271 714 A Ref 805 474 A OM 265 809 Page 23 gt A complete Parts List is available on line at www MillerWelds com 5 14 Connecting 1 Phase Input Power For 240 VAC IO A r a N Y 3 GNDJ P
42. her 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 a moins qu ils naient t pr par s correctement conform ment AWS F4 1 et AWS A6 0 voir les Normes de S curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancher le cable 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 lees e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter un quipement de protection pour le corps fait d un mat riau r sistant et ignifuge cuir coton robuste laine La protection du corps comporte des v tements sans huile comme par ex des gants de cuir une chemise solide des pantalons sans revers des chaussures hautes et une casquette 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 app
43. hese 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 e 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 e Properly install ground and operate this equipment according to its Owner s Manual and national state and local codes e 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 e a Ei d This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord and ground conductor for damage or bare wiring replace immediately if damaged bare wiring can kill Turn off all equipment when not in use Do
44. in 1 ampere 0 125in 125A Select Wire Size Select Wire Speed Amperage 0 023 in 30 90 A S 125A based on 1 8 in material thickness 0 023 in 3 5 in per ampere 3 5 x 125 437 ipm 0 030 in 40 145A d j j ipm inches per minute 0 035in 50 180A 0 030 in 2 in per ampere 2 x 125 A 250 ipm 0 035 in 1 6 in per ampere 1 6 x 125 A 200 ipm y Voltage controls height and Wire speed amperage controls weld width of weld bead penetration wire speed burn off rate Select Voltage Low voltage wire stubs into work High voltage arc is unstable spatter Set voltage midway between high low voltage OM 265 809 Page 36 9 3 Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed Before lowering helmet and pressing trigger be sure wire is no more than 1 2 in 13 mm past end of nozzle and tip of wire is positioned correctly on seam Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension Stickout Solid Wire 3 8 to 1 2 in 9 to 13 mm Cradle Gun and Rest Hand on Workpiece End View of Work Angle Side View of Gun Angle End View of Work Angle Side View of Gun Angle GROOVE WELDS FILLET WELDS S 0421 A 9 4 Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wire feed speed weld current and volta
45. iquement par du personnel qua lifi e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les 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 e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux OM 265 809 Page 8 LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement 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 Demander seulement a des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation L utilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation Si le 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 so
46. les et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at http www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs 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 ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association 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 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g nere des cham
47. m rear until it snaps in place 2 Drive Roll The drive roll includes three different sized grooves The text aligned with the drive roll retaining pin indicates the selected groove see Section 5 15 3 Retaining Pin To secure drive roll locate open slot and push drive roll completely over retaining pin then rotate drive roll to desired slot gt See Section 10 2 for optional drive rolls 024 Groove 030 035 Groove 030 035 V Knurled Groove Table 7 1 Drive Roll Grooves And Wire Type Compatibility 024 024 Solid Wire 030 035 030 035 Solid Wire EE a a 267 893 A OM 265 809 Page 18 E A complete Parts List is available on line at www MillerWelds com 5 8 Removing MIG Gun After Installation To Replace With A Spool Gun Open Pressure Assembl Turn Gi Power Cut Off End Of Wire p y C7 Hold wire tightly to keep it from unraveling Rewind Wire Onto Spool Fasten Loosen Knob Disconnect Gun Trigger End Of Wire To Spool Plug And Remove Gun From Unit See Section 5 6 for gun installation 270 208 A Ref 802 982 A Ref 267 805 A Ref 267 807 A OM 265 809 Page 19 E A complete Parts List is available on line at www MillerWelds com 5 9 Installing Gas Supply LES Obtain gas cylinder and chain to A SIA running gear wall or other Ce stationary support so cylinder cannot fall and break off valve EF DO NOT use Argon Mixed gas regulator flowmeter 1 Cap with CO
48. n 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 249 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 body protection made from durable flame resistant mate rial leather heavy cotton wool Body protection includes oil free clothing such as leather gloves heavy shirt cuffless trousers high shoes and a cap A WELDING can cause fire or explosion AN 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 within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them
49. nflammable SCH OM 265 809 Page 7 LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s 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 Les PI CES MOBILES peuvent causer des blessures e Ne pas s approcher des organes mobiles e 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 re u l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage L EXPLOSION DE LA BATTERIE peut provoquer des blessures e Ne pas utiliser l appareil de soudage pour charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l appareil dispose d une fonctionnalit de charge de batterie destin e cet usage Les PI CES MOBILES peuvent causer des blessures qu 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 e Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection un
50. no power light Secure power cord plug in receptacle see Section 5 13 and 5 14 Replace building line fuse or reset circuit breaker if open Place Power switch in On position see Section 6 1 Reset welding power source supplementary protector if open see Section 7 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 4 4 Secure gun trigger plug see Section 5 6 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 Check for loose connections Replace gun contact tip see gun Owner s Manual Check for proper polarity connections see Section 5 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 6 1 Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts Adjust drive roll pressure See Section 5 15 Change to proper drive roll groove see Section 5 7 Readjust hub tension see Section 5 10 Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove Replace cont
51. nstalling 8 in 203 mm Wire Spool Adapter and retaining ring When a slight force is needed to turn spool ten sion is set Align locking hole in spool with locking pin on spool hub Tools Needed IZ 1 2 in 803 012 267 865 A 5 11 Electrical Service Guide Elec Serv 2014 01 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source In dedicated circuit installations the National Electrical Code NEC allows the receptacle or conductor rating to be less than the rating of the circuit protection device All components of the circuit must be physically compatible See NEC articles 210 21 630 11 and 630 12 60 Hz 240 60 Hz 120 Single Phase Volts AC Input Voltage V 240 15 or 20 Input Amperes A At Rated Output 16 6 ampere individual Max Recommended Standard Fuse Rating In Amperes branch circuit rotected b Time Delay Fuses 2 25 imeda Normal Operating Fuses 3 30 _ fuses or circuit breaker Min Input Conductor Size In AWG 4 14 is required Max Recommended Input Conductor Length In Feet Meters 72 22 See Section Min Grounding Conductor Size In AWG 4 14 SC Reference 2014 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit
52. o ensure it is free of sparks glowing embers and flames 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 Read and understand the Safety Data Sheets SDSs and the manufacturers instructions for adhesives coatings cleaners consumables coolants degreasers fluxes and metals 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 A BUILDUP OF GAS can injure or kill e Shut off compressed gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e 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 lev el is high CYLINDERS can explode if damaged Compressed gas cylinders contain gas under high pressure lf dama
53. off wire Close door held for 3 seconds see Section 6 3 Ref 267 805 A Ref 267 871 A Ref 800 924 D OM 265 809 Page 26 E A complete Parts List is available on line at www MillerWelds com SECTION 6 OPERATION 6 1 Manual EE MILLER ELECTRIC MFG CO APPLETON WI USA 1 Voltage Material Thickness Control Turn control clockwise inside white scale 1 10 to increase voltage see weld parameter chart in welding power source or Section 6 4 2 Process Select Control Turn control to select desired weld process H L Kc Ok i FO Rear View 3 Wire Speed Wire Diameter Control Turn control clockwise inside white scale 10 100 to increase wire feed speed see weld parameter chart in welding power source or Section 6 4 4 Over Temperature Light If unit overheats light turns on and output stops Allow unit to cool before resuming operation This light will also communicate additional unit errors 265 381 A 270 208 A 5 Power Light Power light illuminates when the unit is turned on and powered up 6 Power Switch Use switch to turn unit On or Off OM 265 809 Page 27 gt A complete Parts List is available on line at www MillerWelds com 6 2 Using Auto Set MILLER ELECTRIC MFG CO APPLETON WI USA Blinking Auto Set LED indicates parameter not recommended refer to door chart See weld parameter chart for Auto Set instructions
54. ooting Distortion Distortion contraction of weld metal during welding that forces KEE base metal to move Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Select lower voltage range and or reduce wire feed speed Increase travel speed Weld in small segments and allow cooling between welds Notes OM 265 809 Page 41 9 16 Common GMAW MIG Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtures of shielding gases have been developed over the years The most commonly used shielding gases are listed in the following table Application Gas Short Circuitin Spray Arc Short Circuitin Spray Arc Short Circuitin Spray Arc Steel g P e s P e 3 Steel Stainless Steel Stainless Steel Aluminum Aluminum Argon All Positions All Positions Flat amp Horizontal Flat amp Horizontal O EE Fillet Fillet Flat amp Horizontal Flat amp Horizontal O SE Fillet Fillet Flat amp Horizontal O Argon 5 O gt Fillet Flat amp Horizontal Argon 8 CO e All Positions Fillet Argon 25 Flat amp Horizontal ee I S SE All Positions All Positions4 CO Fillet Argon 50 w CO All Positions
55. 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 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 a la terre de mani re incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous 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 pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande Si l 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 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 de
56. ps lectromagn tiques CEM a certains endroits Le courant issu d un soudage l arc et de proc d s connexes y compris le soudage par points le gougeage le d coupage plasma et les op rations de chauffage par induction cr e un champ lectromagn tique CEM autour du circuit 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 Limiter par exemple tout acc s aux passants ou proc der une valuation des risques individuels 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 les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les cables d un c t et distance de l op rateur Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconna t qu ils provoquent des cancers des malformations cong nitales ou d autres problemes de procr ation Se laver les mains apr s utilisation 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 In
57. r some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in EE EE EE exact part you may need to fix the problem the ISO 9001 Quality System Warranty and service information for your SE particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING J 1 2 13 1 4 1 5 1 6 EE e E Aere E Wakana kas amana yaa Q Wa ee een a are E a amam h w Are Welding Hazards see uyu Lag upya py a inde a une Za au ways Additional Symbols For Installation Operation And Maintenance California Proposition 65 Warnings sevi a A A EIN AE Principal Saftey Standards i rires uu o t dren eee aes Sauna eee ek wrth des ox ews EMP Informat n vico ii ee A oe Oe as wee eae Serres ws SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION
58. raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e a une prise correctement mise a 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 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 et le conducteur de mise la terre afin de s assurer qu il n est pas alt r ou d nud le remplacer imm diatement s il l est Un fil d nud peut entrain er 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 e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e 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 utiliser 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
59. rkening Helmet Lenses Classic Series Only No Labor Fume Extractors Capture 5 Filtair 400 and Industrial Collector Series 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices CoolBelt and CoolBand Blower Unit No Labor Desiccant Air Dryer System External Monitoring Equipment and Sensors Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater RFCS Foot Controls Except RFCS RJ45 Fume Extractors Filtair 130 MWX and SWX Series HF Units ICE XT Plasma Cutting Torches No Labor Induction Heating Power Sources Coolers NOTE Digital Recorders are Warranted Separately by the Manufacturer LiveArc Welding Performance Management System Load Banks Motor Driven Guns except Spoolmate Spoolguns PAPR Blower Unit No Labor Positioners and Controllers Racks Running Gear Trailers Spot Welders Subarc Wire Drive Assemblies Water Coolant Systems TIG Torches No Labor Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor Except Classic X A F gt X X X f FF HF 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG G
60. ropri 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 e Lire et comprendre les fiches de donn es de s curit et les instruc tions du fabricant concernant les adh sifs les rev tements les nettoyants les consommables les produits de refroidissement les d graisseurs les flux et les m taux DES PIECES DE METAL ou DES SALETES peuvent provoquer des EE 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 nerent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e 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 alimentation du gaz comprim en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologue Les CHAMPS ELECTROMAGNETIQUES CEM peuvent affec
61. s Polatity Table socorristas tuba tata eee Gets Gens weal ches Geta ds Changing POP cans dal dass ratas ets fads here Rte Geta te Installing Welding Gun Or Spool GUN es ste Re dete dels PEGS Se dan Changing Drive Roll Or Wire Inlet Guide Removing MIG Gun After Installation To Replace With A Spool Gun e leie BEE leie EE Installing Wire Spool And Adjusting Hub Tension Electrical Service Guide uuu eee A Roa Pe ed ee TA OE a SE Ea Multi Voltage Plug MVP Connection Connecting 120 Vot INbUTRPOWEF 35 0d od Meee eee Bee ak OE EER EE AEG MER ES Connecting 1 Phase Input Power For 240 VAC Threading Welding Wires cutis ada a d s cinema bbl ads Sees een m l oe eee eae SECTION G6 ORERATION EE 6 1 6 2 6 3 6 4 6 5 Manual Sepi a wae 2 Y ayak wees 2 bese dees wee wee we bene UNGA Sele Age E AA oak wee E Ee E eee aa Tee ME W IEParameler Cha gr ee Ee aan SEN CN ee et ee ER E EE De Well Parol ele Suyu uum at ia a aan ua aan EC ae Ee DEE abs ae EE Ne O O O O1 OI QI PS POH N N N N N N N N sech a do sch AH sch SB sch ao eo at zl O G NN OO O OD zl Oona O P GQ NS ch CO OH TABLE OF CONTENTS SECTION 7 MAINTENANCE amp TROUBLESHOOTING 7 1 Routine Maintenance 7 2 Overload Protection 7 3 Drive Motor Protection And Tip Saver Short Circuit Protection 1
62. s 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 larc du proc d de soudag g nere 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 l soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI 249 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque OM 265 809 Page 6 e 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 e Porter un quipement de protection pour le corps fait d un mat riau r sistant et ignifuge cuir coton robuste laine La protection du corps comporte des v tement
63. s manual 4 2 Unit Specifications Do not use information in unit specifications table to determine electrical service requirements See Sections 5 11 5 13 and 5 14 for information on connecting input power Maximyum Open Circuit Voltage DC Uo 115 19 8 Volts DC 20 30 130 Duty Cycle 120 VAC Solid Stainless Flux Cored Wire Feed Speed Range Wire Type Rated Welding Amperage Range Output Amperes Input at Rated Overall Load Output Dimensions 50 60HZ Single Phase Input Voltage and Dia 023 035in 030 035 in 60 600 IPM ae in 0 6 0 9 mm 0 8 0 9 mm 1 5 15 24 m min Width 11 25 in 150 A 21 5 286 mm Volts DC 30 230 Height 12 5 in 40 Duty Cycle 318 mm 240 VAC Solid Stainless Flux Cored Wire Feed Speed Range Wire Type and Dia 023 035 in 030 045 in 60 600 IPM 0 6 0 9 mm 0 8 1 2 mm 1 5 15 24 m min See unit rating label and Section 3 2 4 3 Environmental Specifications A IP Rating IP Rating IP21 This equipment is designed for indoor use and is not intended to be used or stored outside IP21 2014 06 OM 265 809 Page 11 E A complete Parts List is available on line at www MillerWelds com 4 4 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating If unit overheats thermostat s Opens output stops and cooling fan runs Wait fi
64. s sans huile comme par ex des gants de cuir une chemise solide des pantalons sans revers des chaussures hautes et une casquette AIZ 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 soigneusementavec des protections homologu s e Ne pas souder dans un endroit l ou 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 a proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clenc
65. s 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 7 Indique des instructions sp cifiques 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 le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante a 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 a 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 Palimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installez mettez la terre et utilisez correctement cet quipement conform ment son Manuel d Utilisation et aux r glementations nationales gouvernementales 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
66. s 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 BATTERY EXPLOSION can injure e Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose MOVING PARTS can injure e Keep away from moving parts such as fans gt 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
67. s 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 peut donner la mort ou des blessures graves Les dan Indique une situation dangereuse qui si on l vite pas 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 A A A 2 Dangers relatifs au soudage l arc 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 Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entra ner la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels
68. ss reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Millers option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFTT 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
69. stitute 25 West 43rd 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 www osha 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 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler a 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 approch
70. ter les implants me 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 ou 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 louie A 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 Les bouteilles de gaz comprim contiennent du gaz sous haute pression Si une bouteille est endommag 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 excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom ber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais en
71. trer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz comprim r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e Tourner le dos la sortie de vanne lors de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gulateur lors de l ouverture de la vanne e Le couvercle du d tendeur doit toujours tre en place sauf lors que 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 suf fisamment de personnes pour soulever et d placer les bouteil les 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 curit 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 alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service AY HE LA C
72. uns and Subarc SAW Torches 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 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 le
73. urces de haute fr quence maintenir les clateurs une dis tance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE A L ARC risque de provoquer des interf rences e 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 Veiller a ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi 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 ca 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 Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconna t qu ils provoquent des mal formations cong nita
74. will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed If notification is submitted as an online warranty claim the claim must include a detailed description of the fault and the troubleshooting steps taken to identify failed components and the cause of their failure 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 twelve months 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 Auto Darkening Helmet Lenses Series No Labor Engine Driven Welder 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 Transformer Rectifier Power Sources 3 2 Years Parts and Labor Auto Da
75. 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 containers that have held combustibles or on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 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 OM 265 809 Page 2 a Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear body protection made from durable flame resistant material leather heavy cotton wool Body protection includes oil free clothing 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 t

Millermatic 211

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