OM-230 693B 2007−07 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder R Millermatic 252 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.
. A complete Parts List is available at www.MillerWelds.com 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 Wire Feed Output Volts V U0 Rated No-Load Voltage (Average) SECTION 4 − INSTALLATION 4-1.
. A complete Parts List is available at www.MillerWelds.com 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. WELD AMPERES 500 450 400 350 300 If unit overheats, Thermistor (T) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. 250 200 Y Exceeding duty cycle can damage unit and void warranty.
. A complete Parts List is available at www.MillerWelds.com 4-4. Connecting To Weld Output Terminals 4 1 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 Incorrect Installation Y Turn off power before connecting to weld output terminals. 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut Y Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.
. A complete Parts List is available at www.MillerWelds.com 4-6. Connecting Spoolmatic) 15A Or 30A Gun 1 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 2 3 Weld Cable Shielding Gas Hose Route weld cable through opening in front panel. Route gas hose along side panel. 4 Positive Weld Output Terminal Connect weld cable to weld output terminal. 5 Regulator/Flowmeter Route shielding gas hose up to regulator/flowmeter. Connect gas hose to fitting on regulator/flowmeter. 2 .
. A complete Parts List is available at www.MillerWelds.com 4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python . 1 2 3 XR Edge guns prior to serial no. LE079101 require an adapter cord (part no. 195 498). Gun End Gun Liner Wire Outlet Guide Trim excess liner from end of gun so no more than 3/32 in (2.4 mm) of liner extends past wire outlet guide. 4 3/32 in (2.4 mm) 4 Be sure to change drive rolls to the proper size and type. 5 2 Gun Securing Knob Loosen securing knob.
. A complete Parts List is available at www.MillerWelds.com 4-8. Setting Gun Polarity For Wire Type 1 Changing Polarity Polarity Changeover Label Information Always read and follow manufacture’s recommended polarity. Wire Drive Assembly Lead Work Clamp Lead 1 D D + Positive Terminal - Negative Terminal Shown as shipped − Electrode Positive (DCEP): For solid steel, stainless steel, aluminum, or flux core with gas wires (GMAW).
. A complete Parts List is available at www.MillerWelds.com 4-10. Installing Wire Spool And Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. When a slight force is needed to turn spool, tension is set. Installing 1 Or 2 lb Wire Spool Spindle Spindle Install these components onto spindle. 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.
. A complete Parts List is available at www.MillerWelds.com 4-12.
. A complete Parts List is available at www.MillerWelds.com 4-13. Selecting A Location And Connecting Input Power 1 8 =GND/PE Earth Ground 18 in (457 mm) of space for airflow 10 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, 1 804 912-A 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.
. A complete Parts List is available at www.MillerWelds.com 4-14. 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 1 Tools Needed: 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 Tighten scale to set a desired drive roll pressure.
. A complete Parts List is available at www.MillerWelds.
. A complete Parts List is available at www.MillerWelds.com 4-15.
. A complete Parts List is available at www.MillerWelds.
. A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls 1 Voltage Control Turn control clockwise to increase voltage. 2 Wire Speed Control Turn control clockwise to increase wire feed speed. 3 4 4 3 1 Voltmeter Wire Feed Speed Meter 2 . This unit has three automatic timers included in its operation to help save contact tips, gas, and wire: Tip Saver − Weld output shuts off if tip is shorted to work surface.
. A complete Parts List is available at www.MillerWelds.com JOG Mode If the trigger on either gun is held for more than 3 seconds without striking an arc, the unit will automatically shut off weld power (and shielding gas output on MIG gun only), but will feed wire continuously at the preset wire feed speed (which may be faster or slower than Run−in Speed) until trigger is released. Run−in Wire Feed Speed Settings Run−in settings for the MIG and Spool Guns are independently set and stored in unit memory.
. A complete Parts List is available at www.MillerWelds.com 5-2. Voltmeter And Wire Feed Speed Meter Operation 1 1 Voltmeter Welding Status 2 Wire Feed Speed Meter When either a MIG gun or spool gun trigger is pressed and a welding arc is established, the voltmeter displays actual weld voltage. When the gun trigger is released and welding arc extinguished, the voltmeter displays the last actual voltage for 5 seconds and then returns to preset voltage.
. A complete Parts List is available at www.MillerWelds.com 5-4. Timers 4 3 1 1 Voltage Control 2 Wire Speed Control 3 Voltmeter 4 Wire Feed Speed Meter To enter the TIMERS menu press and hold the gun trigger while turning on the power switch until the left meter displays (run), then release trigger. Once in the TIMERS menu, rotate the left knob clockwise (CW) to find the particular item, and rotate the right knob to change the setting.
. A complete Parts List is available at www.MillerWelds.com . Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high. 5-5. Set Up Push Motor Torque (SUP) Or Reset (rES) 4 3 1 1 Voltage Control 2 Wire Speed Control 3 Voltmeter 4 Wire Feed Speed Meter Depress the gun trigger while turning on the power switch until the left meter displays (run).
. A complete Parts List is available at www.MillerWelds.com SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance . Maintain more often Y Disconnect power before maintaining. n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent during severe conditions. l = Replace Reference Every 3 Months l Unreadable Labels Every 6 Months ~ Weld Terminals nl Weld Cables OR ~ Inside Unit n Apply Light Coat Of Oil Or Grease To Drive Motor Shaft 6-2.
. A complete Parts List is available at www.MillerWelds.com 6-4. Aligning Drive Rolls and Wire Guide Y Turn Off power. View is from top of drive rolls looking down with pressure assembly open. Correct 3 Incorrect 4 2 1 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.
. A complete Parts List is available at www.MillerWelds.com 6-5. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 4-13). Replace building line fuse or reset circuit breaker if open (see Section 4-13). Secure gun trigger connections (see welding gun Owner’s Manual). HL.P 001 appears on meters. Turn power switch off and back on, if HL.P 001 appears on meters again, have Factory Authorized Service Agent check unit. HL.
. A complete Parts List is available at www.MillerWelds.com Trouble Remedy No wire feed. Turn Wire Speed control to higher setting (see Section 5-1). Clear obstruction in gun contact tip or liner (see welding gun Owner’s Manual). Readjust drive roll pressure (see Section 4-14). Change to correct size drive rolls (see Section 6-3). Rethread welding wire (see Section 4-14). HL.P 002 appears on meters. Thermistor T is detecting an overheating condition. Wait for unit to cool allowing the fan to run.
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SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1.
229 485-A OM-230 693 Page 33
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.
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 .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 . 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 . 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 9-1. 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 Drive Roll Part No.
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