OM-235 825C 2010−04 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder R R Millermatic Passport Plus And M-10 Gun 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 _2010−03 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_2010−03 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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SECTION 3 − SPECIFICATIONS 3-1. Specifications Input Voltage Rated Welding Output Amperage Range Maximum Open-Circuit Voltage DC 30 − 140 45 110 A @ 19.5 Volts DC, 20% Duty Cycle 115 VAC 80 A @ 18.0 Volts DC, 100% Duty Cycle* Wire Type And Dia 230 VAC 150 A @ 21.5 Volts DC, 20% Duty Cycle 130 A @ 20.5 Volts DC, 60% Duty Cycle Wire Type And Dia Amperes Input at Rated Load Output, 50/60 Hz, Single-Phase KVA KW 23.1 2.69 2.66 16.4* 1.9* 1.
3-3. Duty Cycle And Overheating WELD AMPERES 140 Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. 115 VAC DUTY CYCLE 130 120 110 100 90 80 70 60 10 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. NOTICE − Exceeding duty cycle can damage unit or gun and void warranty.
SECTION 4 − INSTALLATION 4-1. Installing Work Clamp . Tighten connection hardware with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating of the work clamp. 6 5 2 4 1 2 3 4 5 6 3 Route work cable through hole in clamp handle. Secure cable with hardware as shown. 1 Tools Needed: Work Clamp Work Cable From Unit Screw Flat Washer Lock Washer Nut 7/16 in. 7/16 in. 805 460-A 4-2.
4-3. Process/Polarity Table Process Cable Connections Polarity Cable To Gun Cable To Work GMAW − Solid wire with shielding gas DCEP − Reverse polarity Connect to positive (+) output terminal Connect to negative (−) output terminal FCAW − Self-shielding wire − no shielding gas DCEN − Straight Polarity Connect to negative (−) output terminal Connect to positive (+) output terminal 4-4.
4-6. External Shielding Gas Supply 1 Shielding Gas Connector The shielding gas connector allows connecting an external shielding gas supply to the unit. 2 Internal/External Transfer Switch The Internal/External Transfer switch allows changing between the internal or external shielding gas supply. Place switch in the External Gas Supply position. 1 2 . If a welding arc is not established within one second, the gas solenoid turns off to conserve shielding gas. Ref. 803 809-D / Ref. 803 810-E / Ref.
4-7. 115 VAC Input Power Requirements Connect input power cord to a 20 A individual branch circuit. If connecting to a circuit protected by fuses, use a time-delay fuse marked “D”. 4-8. Connecting 1-Phase Input Power For 230 VAC 1 5 =GND/PE Earth Ground 7 4 6 L1 L2 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.
4-9. Electrical Service Guide For 230 VAC 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. . Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not be available.
4-11. Selecting A Location And Connecting Input Power ! 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. ! Do not move or operate unit where it could tip. 1 4 3 18 in. (460 mm) 6 5 8 7 18 in. (460 mm) 2 Ref. 803 812-A / Ref.
4-12. Installing 4 in. (102 mm) Wire Spool And Adjusting Hub Tension Removing 8 in. (203 mm) Spool Components 1 2 3 4 5 6 Hub Nut Brake Adjust Knob Spring Nylon Washer Spool Hub Brake Washer Remove brake adjust knob and spring, and nylon washer. Remove and retain hub nut, spool hub, and brake washer. 6 5 3 1 4 2 4 . For units prior to serial no. LG160043N, order 2 nylon washers (p/n 228 771) and spring (p/n 225 256) to install the 4 in. (102 mm) wire spool. Installing 4 in.
4-13. Installing And Threading Welding Wire Installing Wire And Adjusting Hub Tension: . Hold wire tightly to keep it from unraveling. 1 2 Retaining Nut Hub Tension Adjustment Screw Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining nut. Adjust tension screw so only a slight force is needed to turn spool. Threading Welding Wire: 3 6 in. (150 mm) 2 Pull and hold wire; cut off end. 3 Pressure Assembly Adjustment Knob Lay gun cable out straight.
SECTION 5 − OPERATION 5-1. Controls 1 Voltage Control Turn control clockwise to increase voltage. The Voltage Control range from minimum to 7 is for 115 V input power. The full range from minimum to maximum (10) is for 230 V input power.
5-2. Weld Parameter Chart Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded. 1. Number on left of slash is Voltage Knob Setting. (Example: 4.5 / 55) 2. Number on right of slash is Wire Speed Knob Setting. (Example: 4.5 / 55) 24 ga. 20/22 ga. 115/230V 115/230V Steel Solid Wire ER70S−6 (DCEP) CO 2 100% C25 75% Ar / 25% CO2 Stainless Steel Flux Core E71T−11 (DCEN) Stainless Steel (DCEP) No gas required Tri−Mix 90% He / 7.5% Ar / 2.5% CO2 .024”(0.
NOTE: Settings are approximate. Adjust as required. “---” Means not recommended. Thicker materials can be welded using proper technique, joint preparation and multiple passes. IMPORTANT: Match drive roll groove to diameter of wire being used. Set Tension knob setting to 3 at start. Adjust tension per instructions in the manual. 18 ga. 16 ga. 14 ga. 1/8” 3/16” 115/230V 115/230V 115/230V 115/230V 115/230V 3/35 3/30 3/25 3/40 3/35 3/30 4/50 4/40 4/30 3.5/50 3.5/40 3.5/35 2.5/20 1.
SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. 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 ~ Clean And Tighten Weld Terminals OR ~ Inside Unit ~ Clean Drive Rolls 6-2.
6-3. 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 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/.035 Groove Drive Roll The drive roll consists of two different sized grooves.
6-5. Cleaning Or Replacing Gun Liner Tools Needed: ! Disconnect gun from unit. 8 mm / 10 mm Head Tube Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. 8 mm 10 mm Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Install and tighten new liner. Blow out gun casing. 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.
6-6. Replacing Switch And/Or Head Tube ! 1 Turn Off welding power source and disconnect gun. Remove handle locking nut. 3 2 Slide handle. 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. Remove from vice and turn head tube out by hand. Hand-tighten head tube into cable connector.
SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1.
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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. . This unit can operate for either the internal or an external shielding gas supply. Regulator/ Flowmeter Internal Shielding Gas Bottle Gas Hose External Shielding Gas Supply Gun Work Clamp Workpiece Wire Feeder/ Power Source light mig 5/967 / 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. Low voltage: wire stubs into work High voltage: arc is unstable (spatter) Set voltage midway between high/low voltage. Select voltage and wire feed speed from parameter chart located on inside of door. Voltage controls height and width of weld bead.
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.
8-10. Troubleshooting − Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Good Penetration S-0639 Possible Causes Excessive heat input. Corrective Actions Select lower voltage range and reduce wire feed speed. Increase travel speed. Wrong polarity. Configure polarity as shown in Section 4-4. Always read and follow wire manufacturer’s recommended polarity, and see Section 4-3. 8-11.
8-13. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. S-0640 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase and/or maintain steady travel speed. Wrong polarity. Configure polarity as shown in Section 4-4. Always read and follow wire manufacturer’s recommended polarity, and see Section 4-3. 8-14.
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.
SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Item No. Part No. . . . . . . . . . . . . . . . . . . . . . 169 715 . . . . . . . . . . . . . . . . . . . ♦087 299 . . . . . . . . . . . . . . . . . . . ♦000 067 . . . . . . . . . . . . . . . . . . . ♦000 068 . . . . . . . . . . . . . . . . . . . ♦000 069 . . . . . . . . . . . . . . . . . . . ♦194 010 . . . . . . . . . . . . . . . . . . . ♦194 011 . . . . . . . . . . . . . . . . . . . ♦194 012 . . . . . . . . . . . . . . . . . . . . .
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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.
