OM-253 392B Processes Multiprocess Welding Description Arc Welding Power Source Wire Feeder Multimatic 200 Visit our website at www.MillerWelds.
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.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
TABLE OF CONTENTS SECTION 7 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Changing Drive Roll Or Wire Inlet Guide . . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 7 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.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. D Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
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 & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-5.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 7 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz comprimé en cas de non utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs. LES FILS DE SOUDAGE peuvent provoquer des blessures.
2-5. Principales normes de sécurité 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 Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
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. A complete Parts List is available at www.MillerWelds.com SECTION 3 − INTRODUCTION 3-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the side. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 3-2.
. A complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Specifications For MIG (GMAW) Input Voltage Rated Welding Output 110 A @ 19.5 Volts DC, 20% Duty Cycle 75 A @ 17.75 Volts DC, 100% Duty Cycle* 120 VAC Wire Type And Dia Amperage Range Maximum OpenCircuit Voltage DC 30 − 140 90 22.4 14.6* Solid/Stainless Flux Cored Wire Feed Speed Range .023 - .035 in. (0.6 - 0.8 mm) .030 - .035 in. (0.8 - 0.9 mm) 70 − 425 IPM (1.75 − 10.
. A complete Parts List is available at www.MillerWelds.com 4-4. Dimensions And Weight 9-3/4 in. (248 mm) Weight 29 lb (13.2 kg) 14-1/2 in. (368 mm) 17 in. (432 mm) 253 921-B Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
. A complete Parts List is available at www.MillerWelds.com 4-5. Duty Cycle And Overheating For MIG Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again. 200 180 230VAC NOTICE − Exceeding duty cycle can damage unit and void warranty.
. A complete Parts List is available at www.MillerWelds.com 4-6. Duty Cycle And Overheating For TIG Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again. 200 180 160 230V & 120V 20A NOTICE − Exceeding duty cycle can damage unit and void warranty.
. A complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle And Overheating For Stick Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again. 200 180 160 NOTICE − Exceeding duty cycle can damage unit and void warranty.
. A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Stick Welding Connections ! Turn off unit and disconnect input power before making connections. 1 Positive Weld Output Receptacle Negative Weld Output Receptacle Stick Electrode Holder And Cable Work Clamp And Cable 2 3 4 Connect stick electrode holder cable to the positive weld output receptacle, and connect work clamp to negative weld output receptacle. Ensure all connections are tight. 1 2 3 4 Ref.
. A complete Parts List is available at www.MillerWelds.com 5-2. TIG Welding Connections DCEN (Direct Current Electrode Negative) ! Turn off unit and disconnect input power before making connections. 1 Positive Weld Output Receptacle Negative Weld Output Receptacle TIG Torch And Cable Work Clamp And Cable 2 3 4 1 Connect TIG torch cable to the negative weld output receptacle and connect work clamp to positive weld output receptacle. 4 Ensure all connections are tight.
. A complete Parts List is available at www.MillerWelds.com 5-3. Process/Polarity Table Process Polarity Cable Connections Wire Drive Assembly Cable Work Cable GMAW − Solid wire with shielding gas DCEP − Reverse polarity Connect to positive (+) output receptacle Connect to negative (−) output receptacle FCAW − Self-shielding wire − no shielding gas DCEN − Straight Polarity Connect to negative (−) output receptacle Connect to positive (+) output receptacle 5-4.
. A complete Parts List is available at www.MillerWelds.com 5-5. Wire Gun Connection Inside Unit 6 5 3 1 4 2 Ref. 254 249-A 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob. Insert end of gun through opening in front panel until gun end bottoms against gun block. Tighten knob. 4 Gun End 5 6 Four Pin Trigger Control Cable Receptacle Route trigger control cable through MIG gun hole. Connect plug on end of cable to four pin receptacle inside unit. Trigger Control Cable .
. A complete Parts List is available at www.MillerWelds.com 5-6. Connecting Shielding Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 2 3 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical.
. A complete Parts List is available at www.MillerWelds.com 5-7. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations 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.
. A complete Parts List is available at www.MillerWelds.com 5-9. Multi−Voltage Plug (MVP) Connection Selecting Plug 2 1 3 4 5 ! 6 Do not cut off power cord connector and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product warranty. 7 Connecting Plug To Power Cord MVP Plug1 2010−10 / Ref.
. A complete Parts List is available at www.MillerWelds.com 5-10. Connecting 115 Volt Input Power ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. . The Auto-Line circuitry in this unit automatically links the power source to the primary voltage being applied, either 115 or 230 VAC.
. A complete Parts List is available at www.MillerWelds.com 5-11. Connecting 1-Phase Input Power For 230 VAC 1 5 =GND/PE Earth Ground 7 4 2 Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before connecting input conductors from unit. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.
. A complete Parts List is available at www.MillerWelds.com 5-12. Installing Wire Spool And Adjusting Hub Tension 1 2 Wire Spool Retaining Nut [For 8 in. (203 mm) Spool Only] 1 2 Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Installing 8 in. (203 mm) Wire Spool Adapter used with 8 in. (203 mm) spool only. When a slight force is needed to turn spool, tension is set. Align locking hole in spool with locking pin on spool hub.
. A complete Parts List is available at www.MillerWelds.com 5-13. Threading Welding Wire 1 2 3 4 5 6 7 4 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. 7 Tools Needed: 1 2 3 6 5 . Hold wire tightly to keep it from unraveling. 6 in. (150 mm) Open pressure assembly. Pull and hold wire; cut off end. . Use pressure indicator scale to set a desired Tighten drive roll pressure. Begin with a setting of 2.
. A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Controls 1 Process Select Knob Turn knob to select the desired welding process. 2 Auto-Set Button Press button to turn Auto-Set On or Off. 3 MIG STAINLESS MIG STEEL C25 MIG STEEL C100 TIG 4 LIFT-ARCt REMOTE SELF SHIELDED STICK LIFT-ARCt WIRE/ROD/TUNGSTEN AUTO−SET Material Thickness Buttons Press the Plus (+) or Minus (−) button to select material thickness for the selected process.
. A complete Parts List is available at www.MillerWelds.com 6-2.
. A complete Parts List is available at www.MillerWelds.com 6-3. Entering Setup Menu 1 2 3 MIG STAINLESS MIG STEEL C25 MIG STEEL C100 When unit is turned off, press and hold Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button simultaneously. MIG Turn unit power on. ALUMINUM LIFT-ARCt REMOTE When Display shows MULTIMATIC 200 setup screen, release the two buttons simultaneously. TIG The contrast adjustment screen should be displayed.
. A complete Parts List is available at www.MillerWelds.com 6-4. Adjusting Display Contrast 1 2 Adjustment Knob Material Thickness Plus (+) Button Follow instructions in Section 6-3 to enter the setup menu. The Display Contrast should now appear on the display. MIG STAINLESS MIG STEEL C25 MIG STEEL C100 To adjust display contrast, turn either Adjustment knob. MIG ALUMINUM Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
. A complete Parts List is available at www.MillerWelds.com 6-6. Calibrating Spoolmate 100 1 2 3 Material Thickness Plus (+) Button Left Adjustment Knob Right Adjustment Knob . Spoolmate 100 MIG STAINLESS MIG STEEL C25 ALUMINUM drive motors are unique to this welding power source. Motor calibration is necessary any time a different Spoolmate 100 is connected to the Multimatic 200. TIG Connect Spoolmate 100 to unit. Cut wire flush at nozzle.
. A complete Parts List is available at www.MillerWelds.com 6-7. Viewing Burn-In Information . Burn-In information is for factory and service use only. Follow instructions in Section 6-3 to enter the setup menu. Press Material Thickness Plus (+) button three times after entering setup to enter the Burn-In information screen. Burn-In information displays electrical information unique to the unit.
. A complete Parts List is available at www.MillerWelds.com 6-10. Viewing Process Logs 1 2 Material Thickness Plus (+) Button Process Select Knob Follow instructions in Section 6-3 to enter the setup menu. Press Material Thickness Plus (+) button six times after entering setup to enter the Process Logs screen. MIG STAINLESS MIG STEEL C25 MIG STEEL C100 TIG Process Logs screen displays manual minutes, Auto-Set minutes, weld cycles, and Auto-Set cycles for the selected process.
. A complete Parts List is available at www.MillerWelds.com 6-11. Viewing Error Logs 1 Material Thickness Plus (+) Button Follow instructions in Section 6-3 to enter the setup menu. Press Material Thickness Plus (+) button seven times after entering setup to enter the Process Logs screen. MIG STAINLESS MIG STEEL C25 MIG STEEL C100 Error Logs screen displays unit over-temperature errors, shorted output errors, shorted trigger errors, input voltage errors, and input current errors.
. A complete Parts List is available at www.MillerWelds.com 6-12. Performing A Factory Reset 1 2 Material Thickness Plus (+) Button Auto-Set Button . A Factory Reset will reset the MIG STAINLESS MIG STEEL C25 MIG STEEL C100 primary log data, process log data, and error log data. Contrast settings, motor calibration settings, Spoolmate Calibration settings, Burn-In information, and Software information will all be retained. MIG ALUMINUM Follow instructions in Section 6-3 to enter the setup menu.
. A complete Parts List is available at www.MillerWelds.com SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Disconnect power before maintaining. l = Replace . Maintain more often during severe conditions. Reference Every 3 Months l Damaged Or Unreadable Labels Every 6 Months l Repair Or Replace Cracked Weld Cable OR ~ Inside Unit ~ Clean Drive Rolls 7-2.
. A complete Parts List is available at www.MillerWelds.com 7-3. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place. 2 1 2 .030/.035 Groove 3 .024 Groove Stamped .024 Drive Roll The drive roll consists of two different sized grooves.
. A complete Parts List is available at www.MillerWelds.com Message Error Remedy SHORTED 6-PIN REMOTE ERROR The 6-pin remote has been held down on power up, or the remote has been held too long without initiating an arc. Release the 6-pin remote. BRIDGE CURRENT ERROR Too much current has passed through the inverter bridge circuit of the unit. Cycle the power to clear this error. If this error persists after a power cycle, contact Miller Electric Mfg. Co. service department.
SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1.
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SECTION 9 − MIG WELDING (GMAW) GUIDELINES mig1 2009−12 9-1. Typical MIG Process Connections ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/ Power Source Gun Shielding Gas Gas Workpiece Work Clamp Ref.
9-2. Typical MIG Process Control Settings . These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in. Convert Material Thickness to Amperage (A) (0.001 in. = 1 ampere) 0.125 in. = 125 A .035 in Wire Size Wire Size Amperage Range 0.023 in. 30 − 90 A 0.030 in. 40 − 145 A 0.035 in.
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. 1 1 3 2 2 3 4 5 5 Hold Gun and Control Gun Trigger Workpiece Work Clamp Electrode Extension (Stickout) 1/4 to 1/2 in.
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 voltage.
9-5. Gun Movement During Welding . Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 1 1 2 2 3 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. 3 S-0054-A 9-6.
9-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use shorter electrode extension (stickout). Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
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.
9-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand. Support hand on solid surface or use two hands. 9-15. Troubleshooting − Distortion Distortion − contraction of weld metal during welding that forces base metal to move.
9-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
Problem Probable Cause Remedy Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary. Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on Readjust welding parameters. welding power source. Loose connections at the gun weld cable or work cable. Check and tighten all connections. Gun in poor shape or loose connection inside gun.
SECTION 10 − STICK WELDING (SMAW) GUIDELINES 10-1. Stick Welding Procedure ! Weld current starts when electrode touches workpiece. ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Equipment Needed: Tools Needed: . Always wear appropriate per1 Constant Current Welding Power Source sonal protective clothing. Workpiece Make sure workpiece is clean before welding.
6013 7014 7018 7024 Ni-Cl 308L ALL DEEP EP ALL DEEP 6013 EP,EN ALL LOW GENERAL 7014 EP,EN ALL MED 7018 EP ALL MED SMOOTH, EASY, FAST LOW HYDROGEN, STRONG 7024 EP,EN NI-CL EP FLAT HORIZ FILLET ALL 308L EP ALL USAGE EP 6011 AC PENETRATION 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 DC* 6010 ELECTRODE 450 400 350 300 AMPERAGE RA
10-4. Positioning Electrode Holder 1 2 End View Of Work Angle Side View Of Electrode Angle 1 10-30 90 2 90 Groove Welds 10-30 45 1 2 45 Fillet Welds S-0060 10-5. Poor Weld Bead Characteristics 1 2 3 4 5 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 4 2 3 5 1 S-0053-A 10-6. Good Weld Bead Characteristics 1 2 3 Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1/8 in. (3.
10-7. Conditions That Affect Weld Bead Shape . Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Angle Too Small Correct Angle 10 - 30 Angle Too Large Electrode Angle Drag Spatter Arc Length Too Short Normal Too Long Slow Normal Fast Travel Speed S-0061 10-8. Electrode Movement During Welding .
10-9. Groove (Butt) Joints 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 1 2 2 Square Groove Weld Good for materials up to 3/16 in. (5 mm) thick. 3 1/16 in. (1.6 mm) Single V-Groove Weld Good for materials 3/16 − 3/4 in. (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.
10-12. Weld Test 1 2 3 Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 3 3 2 To 3 in. (51-76 mm) 1/4 in. (6.4 mm) 2 1 2 To 3 in. (51-76 mm) 2 1 S-0057-B 10-13. Troubleshooting Porosity − small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty.
Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Reduce travel speed.
SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2011-06 Whenever possible and practical, use DC weld output instead of AC weld output. 11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten ) . Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference the product packaging to identify the tungsten you are using.
SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) 12-1. Positioning The Torch ! Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using cerium or lanthanum based tungsten instead of thoriated. Thorium dust contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way.
12-2. Torch Movement During Welding Tungsten Without Filler Rod 75 Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod 75 Welding direction Form pool 15 Tilt torch Remove rod Add filler metal Move torch to front of pool. Repeat process. ST-162 002-B 12-3.
SECTION 13 − PARTS LIST 13-1. Recommended Spare Parts Item No. Part No. . . . . . . . . . . . . . . . . . . . . . 235570 . . . . . . . . . . . . . . . . . . . . . . . 43015 . . . . . . . . . . . . . . . . . . . QJL−2330 . . . . . . . . . . . . . . . . . . . . . . 4323R . . . . . . . . . . . . . . . . . . . . . . . DS−1 . . . . . . . . . . . . . . . . . . . . . . T−030 . . . . . . . . . . . . . . . . . . NS−1200B Description Quantity . . Q−150 MIG gun (Includes) . . . . . . . . . . . . . . . . . . . . .
Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) 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.
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 Miller Electric Mfg. Co.
