OM-1325 204 902M 2005−09 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 210 R And M-25 Gun File: MIG (GMAW) 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 _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. 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 Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
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). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette procédure comporte des risques possibles ! Les dangers éventuels sont représentés par les symboles graphiques joints. Y Indique un message de sécurité particulier . Signifie NOTE ; n’est pas relatif à la sécurité. 2-2.
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.
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). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site Internet : www.csa-international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions X Duty Cycle Do Not Switch While Welding Increase On Off Gas Metal Arc Welding (GMAW) Gun Wire Feed Spool Gun Gas Input Gas Output Voltage Input Press To Reset V Wire Feed Output Volts U0 Rated No-Load Voltage (Average) SECTION 4 − INSTALLATION 4-1. Welding Power Source And MIG Gun Specifications Rated Output Amperage Range DC Max. Open Circuit Max Voltage DC 160 A at 24.
4-2. Welding Power Source 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 voltage, or duty cycle before welding. Y Exceeding duty cycle can damage unit and void warranty.
4-4. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. va_curve1 4/95 − 192 436 4-5. Connecting To Weld Output Terminals 1 4 Do not place anything between weld cable terminal and copper bar. 2 Tools Needed: 3 3/4 in (19 mm) 803 778-A Correct Installation Y Turn off power before connecting to weld output terminals.
4-6. Installing Work Clamp 1 2 Work Cable Boot Route cable through front panel opening. Slide boot onto work cable. 3 Negative (−) Output Terminal Connect cable to terminal and cover connection with boot. Close door. 2 1 Tools Needed: 3 3/4 in Ref. 802 474-D 4-7. Installing Welding Gun 1 2 3 1 3 Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob.
4-8. Connecting An Optional Spool Gun 1 1 Barbed Fitting . If spool gun gas hose is equipped with a pre-installed barbed fitting, cut off fitting from end of hose. 2 Connect spool gun gas hose to barbed fitting. 2 Gun Trigger Plug Insert plug into receptacle labeled “SPOOL GUN”, and tighten threaded collar. 3 4 4 Negative (−) Output Terminal Positive (+) Output Terminal Close door. 3 802 998-B 4-9.
4-10. Installing Gas Supply Obtain gas cylinders and chain to running gear, wall, or other stationary support so cylinders 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. 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. 1 4 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical.
4-11. Installing MIG Wire Spool and Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. Installing 1 Or 2 lb Wire Spool Spindle Spindle Install these components onto spindle. When a slight force is needed to turn spool, tension is set. To install either a 1 lb or 2 lb wire spool, follow the procedure as shown in the illustration. Order extra spring Part No. 186 437 Remove these components from spindle.
4-12. Positioning Jumper Links 2 Check input voltage available at site and listed on the machine rating label. 1 Jumper Links Access Door Open door. 2 200 VOLTS 3 230 VOLTS Jumper Link Label Check label − only one is on unit. 3 Input Voltage Jumper Links Move jumper links to match input voltage. Close and secure access door. 153 980−C 1 Tools Needed: 3/8 in Ref. 802 476-C 4-13.
4-14. Selecting A Location And Connecting Input Power 1 8 =GND/PE Earth Ground 10 18 in (457 mm) of space for airflow 7 9 L1 L2 6 4 5 Y Do not move or operate unit where it could tip. 2 1 3 L2 L1 230 VAC, 1 Ref. 802 991-B / 803 766-B Y Installation must meet all National and Local Codes − have only qualified persons make this installation. Y Disconnect and lockout/tagout input power before connecting input conductors from unit.
4-15. Threading Welding Wire 1 2 3 4 5 6 7 4 7 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: 1 2 3 5 6 . 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 Tighten scale to set a desired drive roll pressure. 1 2 3 4 Close and tighten pressure assembly, and let go of wire.
4-16. Using Gun/Cable Holder 1 1 2 3 2 Side Panel Latch Cable Holder Press latch down to release and open door. 4 3 4 Holster (2) Wrap cable around cable holder, and place gun nozzle into holster.
SECTION 5 − OPERATION 5-1. Controls V 40 2 50 60 1 2 3 70 30 20 80 10 1 4 5 6 90 7 100 3 5 4 Ref. 200 034-B 1 Voltage Control Set Voltage control according to the parameter chart for good starting point. Turn control clockwise to increase voltage. OM-1325 Page 20 2 Wire Speed Control Set Wire Speed control according to the parameter chart. Increase or decrease wire speed to obtain desired bead profile and travel speed.
Notes OM-1325 Page 21
5-2. Weld Parameter Chart *Line voltage can affect weld output, settings on this chart are starting values only. You may need to adjust voltage and wire feed speed to optimize your settings. Input Line Voltage* OM-1325 Page 22 Parameter Chart Settings Higher e.g. 240 Volts AC Weld Will Be Hotter Lower Settings 230 Volts AC Use Parameter Chart Inside Door Lower e.g.
204 890 OM-1325 Page 23
SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance . Maintain more often Y Disconnect power before maintaining. during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Blow out or vacuum inside. OR Remove drive roll and carrier. Apply light coat of oil or grease to drive motor shaft. Ref. 802 990 6-2. Supplementary Protector CB1 1 Supplementary Protector CB1 If CB1 opens, wire feeding stops.
6-4. Replacing Gun Contact Tip Y Turn Off power. 1 2 Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. 2 1 Tools Needed: Ref. 800 797-C 6-5. Changing Drive Roll and Wire Inlet Guide 1 2 4 Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 2 Securing Screw Inlet Wire Guide Drive Roll The drive roll consists of two different sized grooves.
6-6. Aligning Drive Rolls and Wire Guide Y Turn Off power. View is from top of drive rolls looking down with pressure assembly open. 3 1 Correct Incorrect 4 2 5 1 2 3 4 5 Drive Roll Securing Nut Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide. Close pressure roll assembly. Tools Needed: Ref. 800 412-A 6-7. Removing Knob From Front Panel Y Turn Off power.
6-8. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit first. 5/16 in, 10 mm Head Tube Remove nozzle, contact tip, and adapter. 5/16 in 10 mm Remove liner. Lay gun cable out straight before installing new liner. Blow out gun casing. To Reassemble Gun: Install and tighten new liner. Cut liner off 3/4 in (20 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter, contact tip, and nozzle. Ref.
6-9. Replacing Switch And/Or Head Tube Y Disconnect gun first. 1 Remove handle locking nut. 3 2 4 Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure. Secure head tube in vice. 5 6 Loosen jam nut. Remove from vice and turn head tube out by hand.
6-10. Troubleshooting Welding Trouble No weld output; wire does not feed. Remedy Secure power cord plug in receptacle (see Section 4-14). Check and replace power switch if necessary. Check supplementary protector CB1, and reset if necessary (see Section 6-2). Replace building line fuse or reset circuit breaker if open (see Section 4-14). Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 4-7 and/or 6-9). Thermostat TP1 or TP2 open (overheating).
SECTION 7 − ELECTRICAL DIAGRAM 204 891-A Figure 7-1.
SECTION 8 − MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections Y 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 Shielding Gas Supply Gas Hose Wire Feeder/ Power Source Gun Work Clamp Workpiece light mig 5/967 / Ref. 802 714 / Ref.
8-2. Typical MIG Process Control Settings NOTE 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 .125 in Convert Material Thickness to Amperage (A) (.001 in = 1 ampere) .125 in = 125 A .035 in Wire Size Amperage Range .023 in 30 − 90 A .030 in .
8-3. Holding And Positioning Welding Gun NOTE 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.
8-4. Conditions That Affect Weld Bead Shape NOTE 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 NOTE 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.
Notes OM-1325 Page 41
SECTION 9 − PARTS LIST 14 . Hardware is common and 22 19 − Fig 9-5 20 18 − Fig 9-4 25 26 28 27 17 16 24 23 21 13 1 − Fig 9-2 6 8 9 7 10 2 − Fig 9-3 3 11 12 15 4 5 not available unless listed. 802 993-C Figure 9-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Main Assembly . . . 1 . . . . . . . . . . . Fig 9-2 . . . 2 . . . . . . . . . . . Fig 9-3 . . . 3 . . . . . . . . . . 605227 . . . 4 . . . . . . . . . . 199192 . . . 5 . . . . . . . . . . 604102 . . . 6 . . . . . . . . . . 052692 . . . 7 . . . . . . . . . . 121614 . . . 8 . . . . . . . . . . 186758 . . . 9 . . . . . . . . . . 602250 . . . 10 . . . . . . . . . . 203482 . . . 11 . . . . . . . . . . 201019 . . . 12 . . . . . . . . . . 193328 .
13 . Hardware is common and 23 − Fig 9-6 27 24 25 26 1 2 3 4 22 5 6 21 7 19 20 8 18 9 17 10 16 11 12 15 14 not available unless listed. 802 989-A Figure 9-2.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-2. Baffle, Center w/Components (Fig 9-1 Item 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . SPOOL HUB ASSEMBLY (INCLUDING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . . . . . . 058427 . . . . RING,RETAINING SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . 085980 . . . . NUT,STL HEX FULL .625-11 . . . . . . . . . . . . . . . . . .
. Hardware is common and not available unless listed. 7 8 6 9 5 4 3 2 1 Ref. 802 988 Figure 9-3. Panel, Rear w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-3. Panel, Rear w/Components (Fig 9-1 Item 2) . . . 1 . . . . . . . . . . 137761 . . . 2 . . . . . . . . . . 148809 . . . 3 . . . . . . . . . . 188706 . . . 4 . . . . . . . . . . . 203711 . . . 5 . . . . . . . . . . 222508 . . . 6 . . . . . . . . . . 204770 . . . . . . . . . . . . . . . . 201022 . . . 7 . . . . . .
. Hardware is common and 4 not available unless listed. 5 3 6 2 7 8 1 9 10 13 12 11 802 987-B Figure 9-4. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-4. Panel, Front w/Components (Fig 9-1 Item 18) . . . 1 . . . . . . . . . . 208359 . . . 2 . . . . . . . . . . 208164 . . . 3 . . . . . . . . . . 208165 . . . 4 . . . . . . . . . . 208207 . . . 5 . . . . . . . . . . 196801 . . . 6 . . . . S2 . . 192373 . . . . . . . . . . . . . . . . 136343 . . . 7 . .
11 12 12 11 9 14 13 15 17 16 10 9 8 18 7 6 5 4 3 2 1 Ref. 800 792-C Figure 9-5.
Item No. Part No. Description Quantity Figure 9-5. M-25 Gun (Fig 9-1 Item 19 ) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 1 1 1 1 2 2 2 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 17 18 . . . . . 200 258 . . . ♦169 724 . . . ♦169 725 . . . ♦169 726 . . . ♦169 727 . . . ♦087 299 . . . ♦000 067 . . . ♦000 068 . . . ♦000 069 . . . . . 169 728 . . . . . 169 729 . . . . . 170 467 . . . . . 170 468 . . . . . 169 730 . . . . . 169 731 . . . .
Item No. Dia. Mkgs. Part No. Description Figure 9-6. Wire Drive And Gears (Fig 9-2 Item 23) 204857 ... 1 .......... ... 2 .......... ... 3 .......... ... 4 .......... ... 5 .......... ... 6 .......... ... 7 .......... ... 8 .......... ... 9 .......... . . . 10 . . . . . . . . . . . . . 11 . . . . . . . . . . . . . 12 . . . . . . . . . . . . . 13 . . . . . . . . . . . . . 14 . . . . . . . . . . ................ ................ ................ . . . 15 . . . . . . . . . . . . . 16 . . . . . . . . . . .
9-7. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: 1 2 3 4 5 V-Grooved rolls for hard wire. U-Grooved rolls for soft and soft shelled cored wires. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). V-Knurled rolls for hard shelled cored wires. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved). Wire Diameter Fraction Decimal Metric Kit No.
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Effective January 1, 2005 (Equipment with a serial number preface of “LF” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. 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.
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.
