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Miller Electric OM-234 016D User's Manual

1. 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 quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement Vap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interference maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder a une distance de 100 metres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conformement a ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes
2. Clean or replace drive roll clean or replace liner see Sections 5 2 and 5 3 OM 234 016 Page 32 5 5 GMAW MIG Aluminum Welding Hints Here are several hints to help you be more successful with your new aluminum feed system MIG welding aluminum requires different techniques than MIG welding mild steel A Before You Start Welding The removal of lubricants from the aluminum base material may be necessary Consult with your local welding distributor for their recommendation on aluminum cleaners Oxide removal should be done after degreasing This should be done with a stainless steel wire brush This can be done with a hand wire brush or with a cup wire brush If a power wire brush is used keep the RPM s and pressures low to reduce smearing the surface of the material which could entrap oxides and impurities under the surface Always use a wire brush that is used only on aluminum to keep from contaminating the base material Contact you local welding distributor or aluminum filler metal representative for recommendations on wire alloys that fit your application Know the alloy of your base aluminum and what conditions the finished part will be subjected to The two most readily available aluminum filler wires are ER4043 and ER5356 Welding Techniques Make sure the welding power source is set up to weld DCEP DC Electrode Positive For MIG welding aluminum you need to use a 10 to 15 degree push travel angle tip and noz
3. 035 0 9 mm i 100 CO 035 0 9 mm No Shielding Gas required Good for outdoor applications 045 1 2 mm Tri Mix 90 He 024 0 6 mm 7 5 Ar 2 5 CO 030 0 8 mm 035 0 9 mm Selecting Wire Gas and Control Settings for Aluminum Aluminum Aluminum f 100 Argon 030 0 8 mm Spool Gu 4043ER 035 0 9 mm M 10 195605 Torch Consumables Liners Suggested Wire Types Polarity f Nozzles y 169715 169716 024 0 6 mm 087299 024 0 6 mm 194010 030 0 8 mm 000067 030 035 0 8 0 9 mm 194011 035 0 9 mm 000068 035 045 0 9 1 2 mm 194012 045 1 2 mm 000069 E Color parameter charts can be downloaded from www MillerWelds com or by ordering from a Miller distributor OM 234 016 Page 22 Selecting Wire Gas and Control Settings NOTE sung are approximate Adjust as required CHANGING Means not recommended Thicker materials can be welded using proper technique POLARITY joint preparation and multiple passes IMPORTANT Match drive roll groove to diameter of wire being used Set Tension DCEP knob setting to 3 at start Adjust tension per instructions in the manual Electrode Positive For Solid Wire 24 ga 22 ga 20 ga 18ga 16 ga 14 ga 1 8 3 16 1 4 5 16 0 6 mm 0 8 mm 0 9 mm 1 2 mm 1 5 mm 1 9 mm 3 2 mm 4 8 mm 6 4 mm 7 9 mm m
4. dl NE H Processes o i er MIG GMAW Welding Description Wire Feeder Spool Gun Spoolmate 100 Series OWNER S MANUAL Visit our website at File Wire Feeder dio www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get 1t done right We know you don t have time to do 1t 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 IT RU E Bl U ES ISR This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick ee warranty in the and easy With Miller you can count on years Ni 00012000 of reliable service with proper maintenance And N for some reason the unit needs repair GUALITY SYSTEM there s a Tr
5. 35 25 3 5 25 4 40 4 5 50 5 60 7 85 1 15 2 20 3 5 39 4 45 6 65 6 5 75 Work Clamp Lead 20 10 3 15 4 25 6 35 3 5 30 3 5 45 4 50 4 5 70 5 80 6 95 Fr 3 5 25 3 5 28 4 45 5 60 5 70 6 85 7 5 95 Quick Change Dual Grooved Drive Rolls Wire Diameters V Smooth V Knurled 202926 220179 202926 202926 For Flux Core or Stainless Wire 225 229 E 225 229 E OM 234 016 Page 23 Notes OM 234 016 Page 24 4 2 Controls For Millermatic Passport Plus Model A Spool Gun Operation On Millermatic Passport Plus Model Cir Ip O Aluminum on Gun ki Steel Mild Steel 30 E o olo o a NY NS 1 Shielding Gas Cylinder For shielding gas connections see welding power source Owner s Manual 2 Valve Open valve on cylinder just before welding Close valve on cylinder when finished welding 3 Process Switch 4 Aluminum Spool Gun Indicator Light Press process switch until Aluminum Spool Gun indicator light turns on 5 Trigger Press trigger to energize welding power source contactor start shielding gas flow and begin wire feed 6 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Speed control see welding power source Owner s Manual or door chart for appropriate setting 7 Voltage Control Arc voltage is controlled by welding power source Voltage cont
6. 7 Polarity Changeover Terminal Block To make proper polarity connection see welding power source Owner s Manual Close door 804 984 A Ref 801 987 OM 234 016 Page 13 3 4 Connecting Spool Gun To Millermatic Passport Plus Incorrect Exposed O rings Correct Gun Not Seated will cause shielding Gun Fully Seated gas leakage OM 234 016 Page 14 1 Drive Assembly 2 Spool Gun 3 Gun Securing Knob 4 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten gun securing knob Spool gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Internal External Transfer Switch Place switch in the External Gas Supply position 7 Polarity Changeover Terminal Block To make proper polarity connection see welding power source Owner s Manual Close door 805 095 A Ref 801 987 3 5 Connecting Spool Gun To Renegade 180 Drive Assembly Spool Gun Gun Securing Knob Gun End Loosen gun securing knob Insert end through opening until it bottoms against drive assembly Tighten gun securing knob Be sure that gun end is tight against drive assembly Ex posed O rings will cause shielding gas leakage Spool gun must be inserted completely to prev
7. For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes C7 Indicates special instructions TN xf 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 Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or po
8. il y a 10 bureaux regionaux Ie t l pho ne de la region 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et a distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les cables autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pres que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 234 016 Page 9 OM 234 016 Page 10 SECTION 3 INSTALLATION 3 1 Specifications Wire Diameter Range nn rea en it qu Overall Dimensions Weight Millermatic 140 030 Thru 035 in o 5 To 365 Length 0 8 Thru 0 9 mm 0 13 To 9 27 mpm Aluminum Wire Millermatic 140 nn a is a Or Flux Cored Wire 5 To 435 ipm Air Cooled in 102 mm DIVA 4 Bu 57 mm 5 6 lb 2 54 kg 0 13 To 11 05 mpm Diameter ee y es a Gun With Cable 023 Thru 035 in Millermatic 180 And SE EP 0 6 Thru 0 9 mm Solid Renegade 180 Dany Aas E LL Wire 65 To 625 ipm 8 in 203 mm 1 65 To 15 8
9. PUSH ROLL 030 035 0 8 0 9 MM is 209 079 SCREW M4 x 0 7 x 16 EE SEE se Ee EE ee 20 RE NE 209 080 SCREW M4X0 7X6 BA rs 186 413 DRIVE ROLL 030 035 0 8 0 9 MM I iese 4199732 2 PUSH ROLL UK lt 023 TTT 22 serie Ee 199 731 DRIVE ROLL UK 023 DEERE SE 186 488 KEY drive roll 2 mm x 7 MM 2 IE 166 4 10 4 INLET GUIDE ss ne SERE ardid DA see 048 834 CLAMP Circ Diane 079 878 CONNECTOR W SOCKETS PORTERA 194 631 NUT Drass Hans ae rien dns AE N 234 233 GEARBOX ASSEMBLY 28 B2 ie 234 234 MOTOR 23 24 ns AE EE dks wee DE EI LS RANCE TERRES 196 398 BUSS BAR interconnecting S DE 186 404 GUN TUBE ASSEMBLY including D A 234 348 HEAD TUBE ASSY Dioni 20630324 INEA iia ne 194 633 ss BARREL sw ei ceils ee true BANE ES 209 080 SCREW M4 x 0 7 x 6 mm ole AT EE N 166408 220 GAS NIPPLE ske ee best re Gen da OO snc RR 186409 2 GAS DIFFUSER crasas OF nina 186 419 CONTACT TIP 030 UT EEN IE 186 406 CONTACT TIP 035 RT arte 199 730 223 CONTACT TIP 023 ren AB AR EA 166 AS cz INOZZUE 2 dados OO rn 111 400 HOSE SAE 187 ID X 410 OD X 8 000 AO tr
10. a Miller distributor OM 234 016 Page 18 Manual Setup CHANGING Refer to chart below to select Voltage and Wire Speed based POLARITY on thickness of metal being welded NN RE SPEED 50 50 70 1 Number on right me ane fe 40 80 of slash is Wire _ 2 ive Speed Knob Setting OK IE Example 4 65 HR Ciamp 2 Number on left of slash is Voltage Rx 4 gt N y Knob Setting Example 4 65 mu Mu PM Electrode Negative 24 ga 22 ga 20ga 18 ga 16ga 14 ga 1 8 3 16 For Flox Core Wire 0 6 mm 0 8 mm 0 9 mm 1 2 mm 1 5 mm 1 9 mm 3 2 mm 4 8 mm 2 40 3 50 3 50 4 65 45 70 5 5 80 10 90 2 32 3 40 3 40 4 45 5 55 55 60 10 65 4 45 5 60 5 5 65 7 80 10 80 4 85 5 40 5 5 45 6 5 50 10 60 2 35 8 40 55 60 10 65 25 32 3 35 4 5 45 10 50 10 50 45 50 4 5 50 6 75 7 95 1095 4 40 5 50 6 60 7 70 10 75 1892 IN QLTAGE 16ga M 10 195605 Torch Consumables Quick Change Dual Grooved Drive Rolls Wire Diameters V Smooth V Knurled gt Nozzles Y 169715 169716 024 0 6mm 087299 024 0 6mm 024 0 6mm 220179 030 0 8mm 000067 030 035 0 8 0 9mm 194011 030 0 8mm 220179 202926 035 0 9mm 000068 035 045 0 9 1 2mm 194014 035 0 9mm 220179 202926 For Flux Core or Stainless Wire 227 931 H 227 931 H OM 234 016 Page 19 C Weld Parameter Chart For Millermatic 140 Model w Factory Set Non Wire Speed Tr
11. any interference problem resulting from the installa tion e 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 electromagneticallycompatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lfinterference 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 234 016 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 Battery posts terminals and related accessories contain lead and lead co
12. hand and body protection e Sparks can cause fires keep flammables away 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 EA so GN MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury 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 43 STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer 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 e The user is responsible for having a qualified electrician prompt ly correct
13. il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements 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 nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont VEtat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 234 016 Page 8 Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes d
14. le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un cable de masse une m me borne de sortie de soudage OM 234 016 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coupe l alimentation 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 DES PI CES CHAUDES peuvent provoquer des br lures graves 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 recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Si la ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les r
15. soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement re specter 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 d air du poste LES TINCELLES VOLANTES ris quent de provoquer des blessures N e Porter un cran facial pour prot ger le visage el les yeux e Affuter l electrode au tungst ne uniquement a la meuleuse dot e de protecteurs Cette manoeuv re est a ex cuter dans un endroit s r lorsque or 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 inflammable P Q S a LES CHARGES ELECTROSTATI QUES peuvent endommager les circuits imprimes e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pieces e Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des bl
16. the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 234 016 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 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 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health S
17. up and positions as well as the welding power supply will all have a great influence on the weldability of the aluminum and your success C Common Problems Troubleshooting e Melt through caused by over heating the base material 1 Increase travel speed Use sequencing to make shorter welds 2 Sequence welds 3 Use thicker material change joint design or welding process to AC TIG 4 Eliminate or reduce gaps e Dirty welds 1 Use push angle instead of drag technique 2 Increase voltage to get into spray transfer if unit output is capable of this process 3 Use proper base metal cleaning techniques stainless steel brush 4 Check for proper shielding gas and wire alloy type e Wire burns back to contact tip during or at the end of the weld 1 Maintain a 3 4 in 19 mm tip to work distance 2 Check to make sure the contact tip size drive rolls and gun liner match the wire diameter that you are using Sometimes an oversized tip can be used The ID should only be one size larger than the wire diameter e Wire bird nests piles up in front of inlet guide on gun 1 Check and adjust drive roll tension 2 Check to make sure drive rolls match wire diameter 3 Replace contact tip if fouled or plugged Sometimes an oversized tip can be used The ID should only be one size larger than the wire diameter OM 234 016 Page 34 SECTION 6 ELECTRICAL DIAGRAMS LUN ASSEMBLY TRIGGER WELD LAOLE 186 451 Figu
18. 0 25 20 4 30 5 35 5 5 45 7 5 60 se 171510 4 25 5 30 5 5 35 7 5 50 oa 2 5 50 3 5 65 4 5 100 S css 2 5 40 3 5 55 4 5 80 5 80 5 5 85 5 5 100 5 5 100 sa 2 5 30 3 5 50 4 5 60 5 70 6 70 6 70 7 80 sa optional Spool Gun Order part no 300371 275 2580 6 75 7 100 7 5 100 vas ee vs 2 65 25 65 6 70 6 5 75 8 5 90 se 9 100 M 10 195605 Torch Consumables Nozzles _ 169715 169716 024 0 6 mm 087299 024 0 6 mm 194010 030 0 8 mm 000067 030 035 0 8 0 9 mm 194011 035 0 9 mm 000068 Quick Change Dual Grooved Drive Rolls V Smooth V Knurled 220179 220179 220179 Wire Diameters 024 0 6 mm 030 0 8 mm 035 0 9 mm 202926 202926 P N 235557 A Ref 235 557 A OM 234 016 Page 27 4 3 Controls For Renegade 180 Model A Spool Gun Operation On Renegade 180 Model A 1 SOM N 7 a Y VO UN N X AU E Spool Gun MIG Gun switch on Renegade 180 must be in Spool Gun position for spool gun to operate 1 Shielding Gas Cylinder For shielding gas connections see welding power source Owner s Manual 2 Valve Open valve on cylinder just before welding Close valve on cylinder when finished welding 3 Spool Gun MIG Gun Switch Place switch in Spool Gun position 4 Trigger Press trigger to energize welding power source contactor start shielding gas flow and begin wi
19. 2 las wrs RER ASS A PLG24 RC24 SPOOLGUN OPTION 234 419 B OM 234 016 Page 37 SECTION 7 PARTS LIST 7 Hardware is common and not available unless listed 804 988 A Figure 7 1 Complete Assembly OM 234 016 Page 38 Item Dia Part No Mkgs No Description Figure 7 1 Complete Assembly 1 PBI es 186 416 TRIGGER SWITCH 2 etes 186 418 PLASTIC HANDLE i s oe ss de SE SE ees sd EEN a TEER EE DE 209 177 HARDWARE KIT Spoolmate case O ee 196 966 SPOOL COVER ASSY including EE N beg 194 622 SPOOL DEFENCE SHELL a tos 194623 vs SPOOL SHAFT ide ie PERL gt ii ESE 194 624 BUSHING RESISTANCE RUBBER Pie T 194 625 LOCATION BUSHING a Or ab wees REEN 194 626 ADJUSTING NUT ere cr eee ee ee RING rtng C clip 140 shaft x 015 thick 5 Seca 194 627 LOCKING SCREW Mal ests reia 187 239 COVER drive rol iss oe HE REED RD caes SEER DEEG 231 107 STRAIN RELIEF cable tala 23110800 SPRING Cable zu cere obit RS ee nen APA 226615 NUT handle plastic nee 193 999 SPRING CPRSN 310 OD x 040 wire x 1 380 os owas 186 415 PRESS ARM W SHAFT C clip washer EA ou 107 208 4 BEARING siria iaa te data HI DE AG 186 414
20. 8 mpm 3 2 Removing MIG Gun From Welding Power Source Cut Off End Of Wire C7 Hold wire tightly to keep it from unraveling AS Rewind Wire Onto Spool Fasten Loosen Knob Disconnect Gun Trigger End Of Wire To Spool Plug And Pull Gun From Unit Ref 802 982 A OM 234 016 Page 11 3 3 Connecting Spool Gun To Millermatic 140 180 Models A Installing Optional Spool Gun Switch In Millermatic 140 180 Models For Renegade 180 And Passport Plus Models Discard switch assembly unit is pre wired for spool gun option Go to Section 3 4 or 3 5 A Turn Off unit and disconnect input power For units prior to Serial No LH210051N use retrokit part no 300409 for installing spool gun switch Remove wrapper from welding power source 1 Welding Power Source Center Baffle 2 Snap in Blank Remove and discard snap in blank from hole in center baffle 3 Switch Assembly 4 Star Washer 5 Jam Nut Remove top jam nut and star washer from switch switch is equipped with two nuts a jam nut and a backing nut Insert switch assembly into center baffle so that keyway in switch shaft is facing up Secure switch to center baffle with star washer and jam nut Tighten jam nut enough to keep switch from rotating 6 Wiring Harness Connect
21. ARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Cont
22. Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards OM 234 016 Page 2 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when no
23. ES 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 If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating 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 an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the wel
24. Les dangers possibles sont montr s par les symboles peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage a l arc gt gt sh Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En presence 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 entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits internes de la machine sont galement sous tension lorsque l a
25. TIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered
26. Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit IX FALLING UNIT can cause injury 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 If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face
27. acking Mode Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded 1 Number on left of 2 Number on right l OLTAG S 2 S slash is Voltage Ns 6 2 ofslash is Wire EAE EED 40 4 Knob Setting d Speed Knob Setting A Example 4 5 55 Example 4 5 55 80 Material suggested Suggested Wire Sizes Wire Types Shielding Gases i Polarity Flow Rate of 20 30 cth Diameters end Wire C Gas Mixture 024 0 6 mm DCEP 75 Ar 25 CO 030 0 8 mm Solid Wire 100 CO 024 0 6 mm ER70S 6 DCEP 030 0 8 mm Fl No Shielding G Baas HIE 080 08 mm J outdoor applications 35 0 9 mm Stair less Tri Mix 90 He 024 0 6 mm Steel DCEP 7 5 Ar 2 5 CO 030 0 8 mm Selecting Wire Gas and Control Settings for Aluminum Aluminum w Aluminum 100 Argon 030 0 8 mm Opt Spool Gun 4043ER 035 0 9 mm M 10 195605 Torch Consumables 169715 169716 024 0 6 mm 087299 024 0 6 mm 194010 030 0 8 mm 000067 030 035 0 8 0 9 mm 194011 035 0 9 mm 000068 035 045 0 9 1 2 mm 194012 E Color parameter charts can be downloaded from www MillerWelds com or by ordering from a Miller distributor OM 234 016 Page 20 Selecting Wire Gas and Control Settings POLARITY NOTE Settings are approximate Adjust as required Means not recommended DCEP Thick
28. approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 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 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 des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 234 016 Page 6 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaut fement ou un incendie Avant de commencer le soudage v rifier s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Ne pas souder dans un en
29. ation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit EE EE SE SE EE GE es es es ese ee ee ee ee ee ee ee ee ee ee ee 9 2 6 IMOMATOR EME 21er a rd De RE Re Se De De DR 9 SECTION 3 INSTALLATION a u a T OER DE de ewe a Ee DR DE DE Dee testes 11 a PECANS sk ER O eed EN onu 11 3 2 Removing MIG Gun From Welding Power Source EE EE EE cece eke ee ek ese ee 11 3 3 Connecting Spool Gun To Millermatic 140 180 Models 12 3 4 Connecting Spool Gun To Millermatic Passport Plus 14 3 5 Connecting Spool Gun To Renegade 180 15 3 6 Installing Wire Spool And Threading Welding Wire 16 SECTION OPERATION cuisine A aan ed Rte A Ad 17 4 1 Controls For Millermatic 140 180 Models 17 4 2 Controls For Millermatic Passport Plus Model 25 4 3 Controls For Renegade 180 Model 28 SECTION 5 MAINTENANCE 8 TROUBLESHOOTING 30 9 12 Rouline Maintenanee nass a taten ns ow dido RE DR te EER GED EERDER kes 30 9 22 Changing Drive ROIS ESS KEER GE bi nei ade peed shoe bine cha
30. d Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion z 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 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
31. d genes dr ve 31 9 34 Changing Einer tac kine N wee OE TEE bee ae OE OO Rene nn eee hoe Ree 32 5 4 MOUDIESNOOHNG acai ast ies ee aids ade anal 32 5 5 GMAW MIG Aluminum Welding Hints es es ee se es ee se ese es ee eee eee teens 33 SECTION 6 ELECTRICAL DIAGRAMS 1 00 cc ee eee eee 35 SECTION 7 PARTS LIST a 2222 2 a dada a ia 38 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _2007 04 Protect yourself and others from injury read and follow these precautions 1 1 A 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 A A I ap 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 sho
32. doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou a 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 Valimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser Tanneau de levage uniquement pour
33. droit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud 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 clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charge de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d electrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantal
34. e s curit Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents telephone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 telephone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci a propos de tels champs Cependant apres avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumula
35. ees 079 974 O RING 500 ID X 103 cs rbr EE DE 234 236 CONNECTOR plug Bs i ET a es 234 237 CABLE ASSEMBLY 12 FT w connector plug OPTIONAL Quantity To maintain the factory original performance of your equipment use only Manufacturers Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 234 016 Page 39 Notes Notes 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 GQ Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS W
36. ent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in Spool Gun position 7 Polarity Changeover Terminal Block To make proper polarity connection see welding power source Owner s Manual Typically DCEP is used for solid and aluminum wire Close door 804 755 B OM 234 016 Page 15 3 6 Installing Wire Spool And Threading Welding Wire 7 Remove thumb screw and spool Tools Needed cover E 3 3 Hub Tension Nut 4 Wire Spool Install soool so wire feeds from top Turn hub tension nut just so a slight drag is felt on the wire spool 5 Push Roll Lower Drive Roll 6 Drive Roll Pressure Adjustment Opening 1 Thumb Screw 2 Spool Cover 7 Drive Roll Release Lever Red 8 Wire Inlet Guide 9 Contact Tip 10 Nozzle Remove nozzle and contact tip Push Release red lever and hold red lever Thread wire through inlet guide past push roll drive roll and out end of gun 2 inches 50 mm Install contact tip and nozzle Reinstall Turn On welding spool cover and thumb screw power source power C7 Drive roll pressure is preset for 030 035 aluminum wire Rotating screw clock wise decreases drive roll pressure and counterclockwise increases pressure Press gun trigger to feed wire to check drive roll Cut off wire r re Turn screw en h revent slipping pressure Turn screw enough to prev
37. ent slipping 804 985 A OM 234 016 Page 16 SECTION 4 OPERATION 4 1 Controls For Millermatic 140 180 Models A Spool Gun Operation On Millermatic 140 180 Models E Spool Gun MIG Gun switch on Millermatic 140 180 must be in Spool Gun position for spool gun to operate 1 Shielding Gas Cylinder For shielding gas connections see welding power source Owner s Manual 2 Valve Open valve on cylinder just before welding Close valve on cylinder when finished welding 3 Spool Gun MIG Gun Switch Switch must be set in Spool Gun position for spool gun to operate 4 Trigger Press trigger to energize welding power source contactor start shielding gas flow and begin wire feed 5 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Speed control see welding power source Owner s Manual or door chart for appropriate setting 6 Voltage Control Arc voltage is controlled by welding power source Voltage control see welding power source Owners Manual or door chart for appropriate setting CS To purge shielding gas line set gun selection switch item 3 to the MIG Gun position Press spool gun trigger to energize gas valve Shielding gas will flow but spool gun will not feed wire Hold trigger in for several seconds to purge gas line Return gun se
38. er materials can be welded using proper technique Electrode Positive joint preparation and multiple passes For Solid Wire IMPORTANT Match drive roll groove to diameter of wire being used Set Tension knob setting to 3 at start Adjust tension per instructions in the manual a D 24 ga 22ga 20ga 18 ga 16ga 14 ga 1 8 3 16 0 6 mm 0 8 mm 0 9 mm 1 2 mm 1 5 mm 1 9 mm 3 2 mm 4 8 mm DCEN e E maia 4 5 32 5 35 6 45 8 60 10 65 2 30 3 5 45 5 5 55 10 60 2 5 25 4 35 6 40 8 50 10 55 5 50 5 5 60 6 5 80 7 90 10 95 sr ARS 5 40 5 5 50 6 5 70 7 75 10 80 with optional Spool Gun Order part no 300371 2 60 3 70 10 75 3 60 3 5 65 10 70 Quick Change Dual Grooved Drive Rolls Wire Diameters V Smooth V Knurled 024 0 6 mm 220179 030 0 8 mm 220179 202926 035 0 9 mm 220179 202926 F 224 940 E 224 940 E OM 234 016 Page 21 D Weld Parameter Chart For Millermatic 180 Model w Factory Set Non Wire Speed Tracking Mode Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded 1 Number on left of NOHAGE 2 Number on right WIRE SPEED slash is Voltage j d of slash is Wire G Knob Setting Speed Knob Setting 50 Example 4 5 55 Example 4 5 55 Suggested Shielding Gases en se Flow Rate of 20 30 cfh Diameters C Gas Mixture 024 024 0 6 mm 6 mm i 75 Ar 25 CO
39. ered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense 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 CONSEQUEN
40. es 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 Verifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil a nu peut entrainer 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 e 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 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 possible de la soudure e lsoler la pince de masse quand pas mis la pi ce pour viter
41. essures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande an OM 234 016 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures a e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion e Seules des personnes qualifi es sont autoris es a enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remetire les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e Nutiliser que les pieces de rechange recom mand es par le constructeur e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles
42. ev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que Tair de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux e sur la peau Le rayonnement de l arc du proc d de soudag genere des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant soudage e Porter un casque de soudage
43. ge 29 SECTION 5 MAINTENANCE 8 TROUBLESHOOTING 5 1 Routine Maintenance Ar cf vd lt A Disconnect power el before maintaining EF Maintain more often during severe conditions Y Check Change To be done by Factory Authorized Service Agent Q Clean x Replace Reference 5 lt WARNIN A NR ey amp ei ey oe YX Gy Every Unreadable Labels Weld Terminals x Damaged Gas Hose vk Weld Cables 3 Months AS max Cords Every 6 m Months OK EN Drive Rolls Inside Unit OM 234 016 Page 30 5 2 Changing Drive Rolls K e Turn Off power at welding power source first 1 Drive Roll Cover Remove cover Changing Push Roll To remove push roll 2 Push Roll Screw 3 Washer 4 Push Roll Remove screw and washer and lift out drive roll To install drive roll Slide drive roll onto shaft and se cure with washer and screw Changing Lower Drive Roll To remove drive roll lt may be necessary to remove drive roll side of gun case to Lower Drive Roll Screw change lower drive roll Washer Lower Drive Roll Drive Roll Key Drive Roll Shaft Remove screw and washer and lift out drive roll Note drive roll key will come out with drive roll To install drive roll Place drive roll key in slot in drive roll shaft Line slot in drive roll up with drive roll key and slide drive roll onto shaft Secure dri
44. ir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter Vouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placerles bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne
45. lection switch to the Spool Gun position before welding l Gl sb5 1 6 92 S 0621 C Ref 802 982 A 804 986 A OM 234 016 Page 17 B Weld Parameter Chart For Millermatic 140 Model w Auto Set Jie 18ga OLTAG 16ga 5 6 4 X 7 Suggested Suggested Wire Sizes Wire Types Shielding Gases Diameters Polarity Flow Rate of 20 30 cfh Solid Wire C Gas Mixture 024 0 6 mm 024 0 6 mm 6 mm ER70S 6 75 Ar 25 CO 030 0 8 mm DCEP Solid Wire 100 CO U sod 024 0 6 mm DCEP 030 030 0 8 mm 8 mm Flux Core No Shielding Gas M E71T 11 required Good for VEL Smm windy or outdoor applications 035 0 9 mm 035 0 9 mm 9 mm Stainl Stainl Tri Mix u Seal a 90 He Ta 7 5 Ar 024 0 6 mm 030 030 0 8 mm 8 mm Selecting Wire Gas and Control Settings for with optional Spool Gun Order part no 300371 EE w ES 100 SET f 030 0 8 mm en Spool Gun ES 035 0 9 mm 0 9 035 0 9 mm NOTE Settings are approximate Cico as required Means not recommended Thicker materials can be welded using proper technique joint preparation and multiple passes IMPORTANT Match drive roll groove to diameter of wire being used Set Tension knob setting to 3 at start Adjust tension per instructions in the manual CS Color parameter charts can be downloaded from www MillerWelds com or by ordering from
46. limentation 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 talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger 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 on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces condition
47. mpounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of
48. ons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES SA er LETES peuvent provoquer des bles sures dans les yeux e Le soudage l caillement le passage de la piece la brosse en fil de fer et le meulage generent des etincelles et des particules metalliques volantes Pendant la periode 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 l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se serv
49. orly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power mili Turn Off inverter disconnect input power and discharge input Capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 234 016 Page 1 FUMES AND GAS
50. ors 7 Switch Connectors 8 Label Locate and separate connectors in wiring harness near label Connect switch connectors to matching connectors in wiring harness Install wrapper on unit Operation Place switch in the position with the spool gun symbol on the label for spool gun operation Place switch in the position with the MIG gun symbol on the label for wire feeder MIG GMAW gun operation When the switch is in the spool gun position spool gun wire feed speed and voltage are controlled by welding power source controls Tools Needed C EE 1 4 5 16 in AS gt LA YT 9 16 in Ref 804 984 A 804 982 A OM 234 016 Page 12 B Connecting Spool Gun To Millermatic 140 180 Incorrect Gun Not Seated Exposed O rings will cause shielding gas leakage Correct Gun Fully Seated 1 Drive Assembly 2 Spool Gun 3 Gun Securing Knob 4 Gun End Loosen thumbscrew Insert end through opening until it bottoms against drive assembly Tighten gun securing knob Spool gun must be inserted completely to prevent leakage of shielding gas 5 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar 6 Spool Gun MIG Gun Switch Place switch in Spool Gun position
51. oubleshooting 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 u ee exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard 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 C Miller Mil_Thank 2005 04 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Tels SYMDOL USAGE arras daros 1 124 Are Weding Hazas cocidos ed 1 1 3 Additional Symbols For Installation Operation And Maintenance ss Es es ee se see 3 1 4 Galifornia Proposition GS Warnings ss WEER ee a street 4 d 5 e o a MAA 4 le EME MTOR MATION erraten RD DA dd At Eu 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 est OVIMbOlesS MISS al dadas taaan ok 5 2 2 Dangers relatifs au soudage l arc SEE EE EE EE EE EE EE EE EE se Es ee Ee es ee Ee es ee se 5 2 3 Dangers suppl mentaires en relation avec l install
52. re feed 5 Wire Feed Speed Control Wire feed speed is controlled by welding power source Wire Speed control see welding power source Owners Manual for appropriate setting 6 Voltage Control Arc voltage is controlled by welding power source Voltage control see welding power source Owner s Manual for appropriate setting C7 To purge shielding gas line set gun selection switch item 3 to the MIG Gun position Press spool gun trigger to energize gas valve Shielding gas will flow but spool gun will not feed wire Hold trigger in for several seconds to purge gas line Return gun selection switch to the Spool Gun position before welding sb5 1 6 92 S 0621 C Ref 804 755 B Ref 804 986 A 804 476 C OM 234 016 Page 28 B Weld Parameters For Renegade 180 Model Select Wire Type Polarity and Shielding Material Thickness sis ENE MES IE ESA Ir Shop Settings Wall or Premise Power 230 V 1 Ph Aluminum 4043 a 0 030 2 0 70 2 0 70 4 0 70 5 0 70 8 0 95 10 100 IE Ee ee H E L HS S CE Field Setting Generator Power Aluminum 4043 DCEP Boss Jam pn Taa en er 0035 4560 6060 1085 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 234 016 Pa
53. re 6 1 Circuit Diagram For Spoolmate OM 234 016 Page 35 4 WARNING e Do not touch live electrical parts e Disconnect input power or stop engine before servicing e Do not operate with covers removed e Have only qualified persons install use or service this unit REFERENCE PCE FT BLK RIBBED lt RC10 BLK RIBBED lt RCA FEE N gt L RCS BLK DCE 5 EE N GRN ORN YEL a a o ROS 1 GRN GRN YEL 37 ia 38 lt lt RC3 8 s1 38 gt E o lt lt RC3 8 27 5 POWER lt lt RE3 7 115V UNITS ONLY K RC3 2 230V UNITS ONLY 312 lt lt RO3 12 RC3 12 AA E AA y AA A age te lt RC1 4 18 BLK BLK gt _ lt RC1 8 RC20 PLG20 lt RC1 5 15 cs 24 VAC 2 lt RCI 6 Wi gt amp ROI NET gt lt re1 2 LED 1 THERMAL 0 ee AUTO SET UNITS en ONLY N re SERE AUTOSET MEE EEN EEN EIE PES REZ TO TRIGGER ave 2 RC2 16 216 j 4 SPOOLGUN AA 3 RCO RED qe BLK Je PLG28 RC28 zm ee En EEE en ee Figure 6 2 Circuit Diagram For Millermatic 140 180 OM 234 016 Page 36 RC3 3 gt cee eco gt gt RED Ti PCT E CONTROL y BOARD 7 KU ele RC1 PLG1 RC2 PLGZ RC2 13 gt s PAN RC3 PLG3 e RC3 4 gt PLG22 RC22 RC2 3 gt lt TP1 Rg SS 2 RC2 2 gt 3 a ae RC2 11 D gt 34 RC26 PLG2B RC3 6 gt 35 RC3 5 gt Rc2 5 gt K3 214 4 202147 lt
54. rol see welding power source Owner s Manual or door chart for appropriate setting sb5 1 6 92 S 0621 C Ref 235 125 B Ref 804 986 A OM 234 016 Page 25 B Weld Parameter Chart For Millermatic Passport Plus Model 24 ga si Min 20 Min 10 5 10 Min 20 Min 10 Min 5 Selecting Wire Gas and Control Settings for Aluminum with AA JC CHANGING POLARITY Reference Key ES DCEN 230 Volt Only Electrode Positive Electrode Negative For ES Wire For Flux Core Wire For Flux Core or Stainless Wire E ollo wen al Drive Wire Drive Work Clamp Lead Lead OM 234 016 Page 26 Selecting Wire Gas and Control Settings NOTE Settings are approximate Adjust as required Means not recommended Thicker materials can be welded using proper technique joint preparation and multiple passes IMPORTANT Match drive roll groove to diameter of wire being used Set Tension knob setting to 3 at start Adjust tension per instructions in the manual 18 ga 16 ga 14 ga 1 8 3 16 1 4 1 4 5 16 3 8 115 230V 7115 230V 115 230V 115 230V 115 230V 115V 230V 230V 230V 3 35 4 50 45 55 5 5 65 7 100 aa S 3 30 440 45 45 5 5 50 6 550 7 50 8 70 9 65 10 80 3 25 4 30 5 35 6 40 6 5 45 7 45 85 55 9 55 10 60 3 40 3 5550 4 65 45 75 5 5 100 ee 3 35 3 5 40 4 50 5 60 5 5170 7 60 7 5 80 8 90 9 5 100 3 30 3 5 35 4 40 5 50 5 5 60 7 50 7 5 65 8 75 10 9
55. rollers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT 8 SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are cov
56. s utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante E 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 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 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 Deverrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier l
57. t in use e Always ventilate confined spaces or use approved air supplied respirator MAGNETIC FIELDS 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 level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition
58. tandards 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 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator Do nat coil or drape cables around your body Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About 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 SECURIT LIRE AVANT UTILISATION fre som 2007 04 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas
59. tion de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques a haute fr quence repr sente un risque a la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent a tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes LAW 5NS telephone 800 463 6727 ou a Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 telephone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 telephone 1 866 512 1800
60. 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 PRINTED IN USA 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com u Miller
61. uld install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground
62. ve roll with washer and screw Reinstall gun case if applicable Tools Needed Reinstall drive roll cover E B 804 987 A OM 234 016 Page 31 5 3 Changing Liner Tools Needed 5 4 Troubleshooting Turn Off power at welding power source first Nozzle Contact Tip 3 Liner Remove and replace liner Reinstall parts as shown fe AM Ref 804 985 A Trouble Remedy No weld output gun feeder does not work Place Power switch on welding power source in the On position see welding power source Owner s Manual Check Spool Gun MIG Gun switch for correct position Erratic weld output Tighten and clean all connections Check for proper weld output polarity connections see Section 4 1A 3 4 or 3 5 Pressing gun feeder trigger does not energize welding power source welding wire is not energized shielding gas does not flow Secure plug from gun feeder trigger cord into 4 socket receptacle on welding power source see Section 3 3B 3 4 or 3 5 Place Spool Gun MIG Gun switch in Spool Gun position see Section 3 3B or 3 5 Wire feeds shielding gas flows but welding wire is not energized Secure spool gun cable connector to wire drive assembly inside welding power source see Section 3 3B 3 4 or 3 5 See Troubleshooting section in welding power source Owner s Manual Wire feeds erratically Check and correct drive roll pressure see Section 3 6
63. zle pointing in the direction of travel See Figure 5 1 Side View Of Gun Tip Angle al 109 150 Direction Of Welding Forehand Push Backhand Drag Technique Technique Figure 5 1 Gun Tip Angle Pulling or using a drag angle will produce porous dirty welds due to a lack of gas coverage The reflective heat and weld puddle that is present when MIG welding aluminum is very hot Holding the tip closer than 3 4 in could lead to the wire burning back to the contact tip and other feeding problems The most common shielding gas for MIG welding aluminum is 100 argon Flow rates of 20 to 30 CFH cubic feet per hour 0 57 to 0 85 m hr are acceptable C25 or argon CO shielding gases are not acceptable OM 234 016 Page 33 e Maintain a 3 4 in 19 mm tip to work distance and have the contact tip recessed approximately 1 8 in inside the nozzle if possible See Figure 5 2 Gas Nozzle Contact Tip To Work Contact Tube Recessed 1 8 Distance 3 4 in 19 mm in 3 2 mm Inside The Nozzle Figure 5 2 Contact Tube Position And Tip To Work Distance e Avoid large weave beads on aluminum If larger fillet welds are needed multiple pass stringer beads will provide better appearance and have less chance of cold lapping melt through and other weld defects e It will be necessary to increase torch travel speed as the base material becomes heated during the welding process e The skill level of the operator joint types fit

Miller Electric OM-234 016D User's Manual

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