OM-211 958L 2009−04 Processes MIG (GMAW) Welding Description Feeder Gun Spoolmatic 30A R w/Special Length Cables 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.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 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 UNIT can cause injury. MOVING PARTS can cause injury. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
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_2007−04 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 quand on a coupé l’alimentation. 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. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. 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 Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. 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 FILS DE SOUDAGE peuvent provoquer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. 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. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher des organes mobiles tels que des ventilateurs.
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). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, 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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SECTION 3 − DEFINITIONS 3-1. WEEE Label (For Products Sold Within The EU) Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. 3-2.
SECTION 4 − INSTALLATION 4-1. Specifications Wire Diameter Range .025 Thru 1/16 in. (0.6 Thru 1.6 mm) Aluminum Wire .025 Thru .045 in. (0.6 Thru 1.1 mm) Hard Or Cored Wire Approximate Wire Feed Range 70 To 875 ipm (1.7 To 22.2 mpm) Cooling Method Air Cooled Maximum Spool Size 4 in. (102 mm) Diameter Weld Circuit Rating 100 Volts, 200 Amperes, 100% Duty Cycle Using Argon Shielding Gas Overall Dimensions IP Rating IP 23 Length: 15-3/8 in. (390 mm) Width: 2-1/2 in. (64 mm) Height: 10-3/4 in.
4-3. Installing Wire Spool And Threading Welding Wire 1 2 3 4 8 Top Cover Canister Canister Cover Thumbscrew (Canister Cover) Loosen thumbscrew and remove cover. 7 5 Wire Spool Loosen wire from spool, cut off bent wire, and pull 6 in (150 mm) of wire off spool. 6 Pressure Roll Assembly Lift arm and open pressure roll assembly. 7 8 6 Canister Inlet Guide Drive Roll Groove . For wire sizes .035 in (0.9 mm) and smaller use small groove, and .047 in. (1.2 mm) and 1/16 in. (1.6 mm) use large groove.
4-5. Connecting To 24 Volt Weld Control 1 Gas Hose Connect fitting to regulator/flowmeter (see Section 4-7). 1 4 3 2 2 3 24 Volt Weld Control Trigger Control Cord Insert plug into receptacle, and tighten threaded collar. 4 Weld Cable Connect to positive (+) weld output terminal on welding power source according to its Owner’s Manual. Tools Needed: 1-1/8, 5/8 in 150 917-G 4-6. Connecting To 115 Volt Weld Control 1 2 115 Volt Weld Control Gas Hose Connect to regulator/flowmeter.
4-7. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 2 Cap Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 4 Cylinder Regulator/Flowmeter Install so face is vertical. 1 5 Gas Hose Connection Fitting has threads. 6 5/8-18 right-hand Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour).
4-8. Adjusting Drive Roll And Spool Brake Pressure 1 2 3 Top Cover Canister Cover Thumbscrew Loosen thumbscrew and remove cover. 4 Spool Cut welding wire off at contact tip. Retract wire onto spool and secure. 5 5 1 Spool Brake Thumbnut Grasp spool in one hand and turn while adjusting spool brake thumbnut. When a slight force is needed to turn spool, tension is set. Do not overtighten. 2 3 Reinstall canister cover. Thread welding wire (see Section 4-3).
SECTION 5 − OPERATION 5-1. Controls 1 Trigger Press trigger to energize welding power source contactor (if applicable), start shielding gas flow, and begin wire feed. For shielding gas preflow and postflow, lightly press trigger before and after welding. 2 Wire Speed Control Use control to adjust wire feed speed. The numbers in the opening are not a wire feed speed and are for reference only. 1 2 Ref. 147 741-F 5-2.
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! . Maintain more often Disconnect power before maintaining. during severe conditions. 3 Months Replace Damaged Or Unreadable Labels Clean And Tighten Weld Terminals Replace Damage Gas Hose Repair Or Replace Cracked Cables And Cords 6 Months Blow Out Or Vacuum Inside Clean Drive Rolls 6-2. Changing Gun Contact Tip Remove nozzle 1 Nozzle 2 FasTip Unscrew FasTip. Install new FasTip. 2 1 Ref.
6-3. Replacing Head Tube Liner The standard head tube liner will accommodate wire diameters from .030-1/16 wire size. 1 2 3 5 Cover Screw Clamp Loosen clamp screws and remove clamp. 4 Head Tube Remove head tube from gun. 4 2 3 1 4 5 Liner Pull liner out of head tube. Insert liner into head tube and reinstall head tube onto gun. . A twisting motion may be need- ed to feed liner thru head tube. Tool Needed: 5/32 in Ref.
6-4. Gun Drive Assembly Maintenance Retract wire onto spool. 1 2 This tab helps prevent burnback caused by welding arcs inside the contact tip. This tab may be removed to provide an insulated drive roll. (If tab is removed, a smaller diameter contact tip is recommended. See options in Parts List.) Lightly grease top of tab before reinstalling. 3 3 1 Setscrew Current Pick-Up Tab Drive Roll Use wire brush to clean drive roll.
6-5. Replacing Canister Inlet Guide 1 2 Top Cover Pressure Roll Assembly Cut off welding wire where it enters pressure roll assembly area. 3 1 7 Nozzle Pull wire out nozzle. 6 5 2 4 4 5 Thumbscrew Canister Cover Loosen thumbscrew and remove cover. 6 7 Wire Spool Spool Brake Thumbnut Loosen thumbnut, retract wire onto spool, secure, and remove spool. 8 3 Canister Inlet Guide Turn counterclockwise to remove. Install new guide. Reinstall spool and thread welding wire (see Section 4-3).
6-7. Replacing Diffuser Turn Off welding power source. 1 Nozzle 2 FasTip To remove, see Section 6-2. 3 Diffuser Remove diffuser and replace. 3 2 1 Tools Needed: 3/8 in Ref. 803 348-G 6-8. Troubleshooting Trouble Remedy No weld output; gun/feeder does not Secure weld control plug in 115 volts AC receptacle (see weld control Owner’s Manual). work. Place Power switch on welding power source in the On position (see welding power source Owner’s Manual). Erratic weld output.
SECTION 7 − ELECTRICAL DIAGRAM 195 712-B Figure 7-1.
67 OM-211 958 Page 24 62 18 19 3 Figure 8-1. Complete Assembly 20 13 11 12 21 22 17 23 24 25 29 8 26 27 28 65** 30 31 32 64 33 33 34 36 35 66 9 37 63 61 60 44 42 43 38 59 46 69 68 56 58 57 40 41 39 55 45 47 48 62 49 50 51 52 54 53 not available unless listed. 10 6 70 5 . Hardware is common and 7 15 16 1 4 SECTION 8 − PARTS LIST Ref.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Complete Assembly . . . 1 . . . . . . . . . . . . . 214 745 . . Cover (Included With Item 62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . 133 362 . . Strain Relief, Cable . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Complete Assembly (Continued) . . . 52 . . . . . . . . . . . . . 000 364 . . Ring, Retainer Ext .145 Shaft Grv X .025Thk . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 53 . . . . . . . . . . . . . 132 526 . . Cover, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 54 . . . . . . . . . . . . . 132 528 . . Screw, Thumb Canister . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST INCLUDING CONSUMABLES Item Number 1 2 3 4 5 .030−1/16” WIRE STANDARD INSULATOR .030−1/16” WIRE .035−1/16” WIRE .030−1/16” WIRE (231 512) COLLARED INSULATOR (227 749) (#232 284) XR-A Spoolmatic Barrel Assy 6.0” STRAIGHT (#221 087) (231 511) TAPERED INSULATOR Ref. 803 909-A / 803 932 / 803 933 / 803 934 Figure 9-1.
Item No. Part No. Description Quantity Figure 9-1. Consumables Flowchart Table 9-1. Nozzles . . . 1 . . . . . . . . . ♦176238 . . Nozzle, Spot Flat (Requires Diffuser 209099, Used With Any Heavy Duty FasTipt Contact Tip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . ♦176240 . . Nozzle, Spot Inside Corner (Requires Diffuser 209099, Used With Any Heavy Duty FasTipt Contact Tip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Part No. Description Quantity Figure 9-1. Consumables Flowchart (Continued) Table 9-5. Value Multi−Turn Contact Tips* ... ... ... ... ... ... ... 2 2 2 2 2 2 2 ........ ........ ........ ........ ........ ........ ........ ♦071 825 ♦054 202 ♦054 201 ♦199 593 ♦044 006 ♦047 566 ♦202 933 .. .. .. .. .. .. .. .030 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .035 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
Effective January 1, 2009 (Equipment with a serial number preface of LK 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.
