OM-225 311G 2010−03 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic 140 Auto−Set And 180 Auto-Set And M-10 Gun ™ R ™ 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 8 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Holding And Positioning Welding Gun . . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2009−08 7 Protect yourself and others from injury — read and follow these precautions. 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. 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. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
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.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2009−08 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 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. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
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 protecteur 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. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com).
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. A complete Parts List is available on-line at www.MillerWelds.com SECTION 3 − SPECIFICATIONS 3-1. Specifications A. 115 VAC Model w/Auto−Sett Rated Welding Output 90 A @ 18 Volts DC, 20% Duty Cycle 30 − 140 63 A @ 21 Volts DC, 20% Duty Cycle* Wire Type And Dia Maximum Open-Circuit Voltage DC Amperage Range Solid KVA KW 20 2.8 2.4 15* 2.1* 1.8* 28 Stainless .024 - .030 in. (0.6 - 0.8 mm) Amperes Input at Rated Load Output 115 V, 60 Hz, Single-Phase .023 - .030 in. (0.6 - 0.
. A complete Parts List is available on-line at www.MillerWelds.com 3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. A. 115 VAC Model NOTICE − Exceeding duty cycle can damage unit and void warranty. 20% Duty Cycle at 90 Amps 2 Minutes Welding 8 Minutes Resting B.
. A complete Parts List is available on-line at www.MillerWelds.com 3-3. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. A. 115 VAC Model 30 AMPERES 25 20 MAX MIN 15 10 5 0 0 20 40 60 80 100 120 140 160 VOLTS B.
. A complete Parts List is available on-line at www.MillerWelds.com SECTION 4 − INSTALLATION 4-1. Installing Welding Gun 1 2 3 Drive Assembly Gun Securing Knob Gun End Loosen knob. Insert end of gun through opening in front panel until it bottoms against drive assembly. Tighten knob. 4 3 Gun Trigger Plug Insert into receptacle, and tighten threaded collar. 4 Close door. 1 2 . Be sure that gun end is tight against drive assembly. 3 3 Correct Incorrect Ref. 802 982-A / Ref. 801 987 4-2.
. A complete Parts List is available on-line at www.MillerWelds.com 4-3. Work Cable Routing Inside Unit 2 1 2 Work Cable Output Terminal Block Insert work cable through opening in front panel and route along back of front panel to output terminal block. 1 Close door. Ref. 802 982-A 4-4.
. A complete Parts List is available on-line at www.MillerWelds.com 4-6. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. . DO NOT use Argon/Mixed gas regulator/flowmeter with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter and hose. 1 4 2 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.
. A complete Parts List is available on-line at www.MillerWelds.com 4-7. Selecting A Location And Connecting Input Power For 115 VAC Model 1 2 Rating Label Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required. 3 Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m). ! ! Do not move or operate unit where it could tip. 1 18 in.
. A complete Parts List is available on-line at www.MillerWelds.com 4-8. Selecting A Location And Connecting Input Power For 230 VAC Model ! Do not move or operate unit where it could tip. 18 in. (457 mm) of space for airflow 1 6 =GND/PE Earth Ground 8 ! 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.
. A complete Parts List is available on-line at www.MillerWelds.com 4-9. Electrical Service Guide For 230 VAC Model Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 60 Hz Single Phase 230 Input Voltage (V) 21.
. A complete Parts List is available on-line at www.MillerWelds.com 4-11. Threading Welding Wire 1 2 3 4 5 6 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. 4 6 Tools Needed: 1 2 3 1 5 2 . Hold wire tightly to keep it 3 from unraveling. 4 in. (102 mm) 6 in. (150 mm) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. .
. A complete Parts List is available on-line at www.MillerWelds.com 4-12. Removing MIG Gun From Welding Power Source Cut Off End Of Wire Open Pressure Assembly Knob . Hold wire tightly to keep it from unraveling. Rewind Wire Onto Spool, Fasten End Of Wire To Spool Loosen Knob, Disconnect Gun Trigger Plug, And Pull Gun From Unit Ref.
. A complete Parts List is available on-line at www.MillerWelds.com 4-13. Installing Switch For Optional Spool Gun ! 1 Turn Off unit, and disconnect input power. . For units prior to Serial No. LH210051N, use retrokit part no. 300409 for installing spool gun switch. 2 Remove wrapper from welding power source. 1 1 2 3 Welding Power Source Center Baffle Snap-in Blank Remove and discard snap-in blank from hole in center baffle.
. A complete Parts List is available on-line at www.MillerWelds.com 4-14. Connecting Spool Gun To Millermatic 140/180 6 1 2 3 4 7 Drive Assembly Spool Gun Gun Securing Knob 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 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar.
. A complete Parts List is available on-line at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls For 115 VAC Model w/Auto-Set 1 6 2 3 5 4 227 748-G 1 Wire Speed Control Turn control clockwise inside white scale (10-100) to increase wire feed speed. (see weld parameter chart in welding power source or Section 5-3). 2 Voltage Control Turn control clockwise inside white scale (1-10) to increase voltage (see weld parameter chart in welding power source or Section 5-3).
. A complete Parts List is available on-line at www.MillerWelds.com 5-2. Controls For 230 VAC Model w/Auto-Set 1 6 2 3 5 4 Ref. 233 619-D 1 Wire Speed Control Turn control clockwise inside white scale (10-100) to increase wire feed speed. (see weld parameter chart in welding power source or Section 5-4). 2 Voltage Control Turn control clockwise inside white scale (1-10) to increase voltage (see weld parameter chart in welding power source or Section 5-4).
. A complete Parts List is available on-line at www.MillerWelds.com 5-3. Weld Parameter Chart For 115 VAC Model w/Auto−Set Auto−Sett − SIMPLE SETUP FOR WELDING MILD STEEL Example: .030” diameter wire, welding 18 ga. material. .024” .030” t Se o− ut A t Auto−Set* WELD WIRE DIAMETER MATERI AL TH IC KN ES S Activate Auto−Sett by selecting the diameter of the welding wire with the WIRE SPEED knob. Auto−Set light comes on. Select thickness of the mild steel being welded with the VOLTAGE knob.
. A complete Parts List is available on-line at www.MillerWelds.com Manual Setup Refer to chart below to select Voltage and Wire Speed based on thickness of metal being welded. 1. Number on right of slash is Wire Speed Knob Setting. (Example: 4 / 65) ATERI AL TH t M IC et KN −S E o SS ut A 2. Number on left of slash is Voltage Knob Setting. (Example: 4 / 65) 4.5/70 5.5/80 10/90 2/40 3/50 3/50 4/65 2/32 3/40 3/40 4/45 5/55 4/45 5/60 5.5/65 4/35 5/40 5.5/45 6.5/50 10/60 5.
. A complete Parts List is available on-line at www.MillerWelds.com 5-4. Weld Parameter Chart For 230 VAC Model w/Auto−Set Auto-Sett - SIMPLE SETUP FOR WELDING MILD STEEL Example: .030” diameter wire, welding 1/8” material. .024” .030” Auto-Set* WELD WIRE DIAMETER t ATERIAL THIC t M 14ga KN Se E o ut 16ga VOLTAGE 1/ 8” SS A 5 6 18 ga 4 3 7 8 3/ 16” Activate Auto-Sett by selecting the diameter of the welding wire with the WIRE SPEED knob. Auto-Sett light comes on.
. A complete Parts List is available on-line at www.MillerWelds.com Manual Setup Refer to chart below to select Voltage and Wire Speed based on thickness of metal being welded. 1. Number on right of slash is Wire Speed Knob Setting. (Example: 4.5 / 65) ATE RIA L TH IC ttM 14 ga KN Se E to O LTA G E 1/ 8” SS u V 16 ga A 5 6 18 ga 4 7 3 8 2. Number on left of slash is Voltage Knob Setting. (Example: 4.5 / 65) 3 /16” 24 ga. 22 ga. 20 ga. 18 ga. 16 ga. 14 ga. 1/8” 1/4” 5/16” 3/16” (0.6mm) (0.8mm) (0.
. A complete Parts List is available on-line at www.MillerWelds.com SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent . Maintain more often Disconnect power before maintaining. during severe conditions. l = Replace Reference Every 3 Months l Unreadable Labels Every 6 Months ~ Weld Terminals nl Weld Cables OR ~ Inside Unit 6-2.
. A complete Parts List is available on-line at www.MillerWelds.com 6-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place. 2 1 2 3 Stamped .024 Retaining Pin To secure drive roll, locate open slot and push drive roll completely over retaining pin, then rotate drive roll 1/4 turn to closed slot. 3 .030/.
. A complete Parts List is available on-line at www.MillerWelds.com 6-6. Cleaning Or Replacing Gun Liner Tools Needed: ! Disconnect gun from unit. 8 mm / 10 mm 1 Head Tube 2 10 mm 8 mm Remove liner. Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. 3 Blow out gun casing. To Reassemble Gun: Install and tighten new liner. Lay gun cable out straight before installing new liner. Cut liner off 3/4 in. (20 mm) (3/8 in. [9.5 mm] for aluminum) from head tube.
. A complete Parts List is available on-line at www.MillerWelds.com 6-7. Replacing Switch And/Or Head Tube ! 1 Turn Off welding power source /wire feeder and disconnect gun. Remove handle locking nut. 3 Slide handle carefully so wires do not break. 2 Remove switch housing. Install new switch and connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube, continue to end of figure. 4 Secure head tube in vice. 5 6 Loosen jam nut.
. A complete Parts List is available on-line at www.MillerWelds.com 6-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 4-7 or 4-8). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 5-1 or 5-2). Reset welding power source supplementary protector if open. No weld output; wire does not feed; fan Thermostat TP1 open (overheating).
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SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1.
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SECTION 8 − MIG WELDING (GMAW) GUIDELINES mig1 2009−12 8-1. 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.
8-2. Typical MIG Process Control Settings . These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. 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.
8-3. Holding And Positioning Welding Gun . Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. 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.
8-4. Conditions That Affect Weld Bead Shape . Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.
8-5. Gun Movement During Welding . Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 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 8-6.
8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use shorter electrode extension (stickout). Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
8-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics. Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
8-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Unsteady hand. Support hand on solid surface or use two hands. 8-15. Troubleshooting − Distortion Distortion − contraction of weld metal during welding that forces base metal to move.
8-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
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 9 − PARTS LIST . A complete Parts List is available on-line at www.MillerWelds.com 9-1. Recommended Spare Parts Item No. Part No. . . . . . . . . . . . . . . . . . . . . . 169 715 . . . . . . . . . . . . . . . . . . . ♦087 299 . . . . . . . . . . . . . . . . . . . ♦000 067 . . . . . . . . . . . . . . . . . . . ♦000 068 . . . . . . . . . . . . . . . . . . . ♦000 069 . . . . . . . . . . . . . . . . . . . ♦194 010 . . . . . . . . . . . . . . . . . . . ♦194 011 . . . . . . . . . . . . . . . . . . .
Notes
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
Effective January 1, 2010 (Equipment with a serial number preface of MA 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.
