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Miller Electric MW 140 Plus manual

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Table of contents for the manual

  • Page 1

    MW 140 Plus And H-10 Gun ® For W arranty Claims And T echnical Support, Contact: Milweld Inc., National Distributor P .O. Box 338, Hortonville, WI 54944-0338 T el 920-779-0916 Fax 920-779-0924 Processes Description MIG (GMA W) Welding Flux Cored (FCA W ) W elding Arc Welding Power Source And Wire Feeder OM-219 316C 2006 − 10[...]

  • Page 2

    [...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 9 − MIG WELDING (GMA W) GUIDELINES 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. T ypical MIG Process Connections 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. T ypical MIG Process Control Settin[...]

  • Page 5

    OM-219 316 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety me[...]

  • Page 6

    OM-219 316 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watchin[...]

  • Page 7

    OM-219 316 Page 3 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.[...]

  • Page 8

    OM-219 316 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A W[...]

  • Page 9

    OM-219 316 P age 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les utili sés Sy mbole graphique d’aver tis s ement ! Attent ion ! Cett e pr o- cédur e c omporte d es risques p[...]

  • Page 10

    OM-219 316 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe[...]

  • Page 11

    OM-219 316 P age 7 2-3 . Da ngers supplé mentair es en relation avec l’ins talla tion, le f onctionneme nt et la m ainte nance Risque D’INCENDIE OU D’EXPLO- SION. 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 [...]

  • Page 12

    OM-219 316 Page 8 2-5. Princi pales norm es de sécurit é Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el[...]

  • Page 13

    OM-219 316 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperage V V oltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output V oltage Input Of f On Do Not Switch While W elding Gas Metal Arc W elding (GMAW) Wire Feed SECTION 4 − SPECIFICA TIONS 4-1. Specifications Rated W elding Output Amperage Range Max[...]

  • Page 14

    OM-219 316 Page 10 4-2. 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. Y Exceeding duty cycle can damage unit or gun[...]

  • Page 15

    OM-219 316 Page 1 1 4-3. V olt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 − 217 624-A RANGE 4 RANGE 3 RANGE 2 RANGE 1 0 10 20 30 40 50 60 70 80 90 100 1 10 120 130 140 150 160 0.0 5.0 1[...]

  • Page 16

    OM-219 316 Page 12 SECTION 5 − INST ALLA TION 5-1. Installing Welding Gun 803 71 1-A 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew . Insert end through opening until it bottoms against drive assembly . Tighten thumbscrew . W elding gun must be inserted completely to prevent leakage of shielding gas. 4 Gun Trigger Leads In[...]

  • Page 17

    OM-219 316 Page 13 5-3. Process/Polarity T able Process Polarity Cable Connections P rocess P o l ar i ty Cable T o Gun Cable T o Work GMA W − Solid wire with shield- ing gas DCEP − Reverse polarity Connect to positive (+) out- put terminal Connect to negative ( − ) output terminal FCAW − Self-shielding wire − no shielding gas DCEN − St[...]

  • Page 18

    OM-219 316 Page 14 5-5. 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 Cap 2 Cylinder V alve Remove cap, stand to side of valve, and open valve slightly . Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter Inst[...]

  • Page 19

    OM-219 316 Page 15 5-6. Selecting A Location And Connecting Input Power 1 Rating Label 2 Grounded Receptacle A 1 15 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 fo r up to 50 ft (15 m) or 12 A WG for 50 up to 200 ft (61 m). Y Special installa[...]

  • Page 20

    OM-219 316 Page 16 5-7. Installing Wire Spool And Adjusting Hub T ension When a slight force is needed to turn spool, tension is set. 1/2 in T ools Needed: 803 012 / 803 013 -B / Ref. 802 971-C Installing 8 in (203 mm) Wire Spool Installing 4 in (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Retaining ring used wit[...]

  • Page 21

    OM-219 316 Page 17 5-8. Installing Contact Tip And Nozzle T ools Needed: Ref. 802 399-A Y T ur n off welding power source. 1 Nozzle Remove nozzle. 2 Contact Tip 3 Tip Adapter Thread welding wire through gun (see Section 5-9). Slide contact tip over wire and tighten tip into tip adapter . Install nozzle. Flux Nozzle MIG Nozzle Use with flux cored wi[...]

  • Page 22

    OM-219 316 Page 18 5-9. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. T ools Needed: Pull and hold wire; cut off end. 4 in (102 mm) Remove gun nozzle and contact tip. Open pressure assembly. Make sure feed roll is set to correct groove to[...]

  • Page 23

    OM-219 316 Page 19 SECTION 6 − OPERATION 6-1. Controls 1 Wire Speed Control Us e control to select a wire feed speed. As V oltage switch setting increases, wire speed range also increases (see weld setting label in welding power source or Section 6-2). 2 Power Switch 3 V oltage Switch The higher the selected number , the thicker the material that[...]

  • Page 24

    OM-219 316 Page 20 6-2. W eld Parameter Chart[...]

  • Page 25

    OM-219 316 Page 21 217 618-A[...]

  • Page 26

    OM-219 316 Page 22 SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean monthly . Or 7-2. Overload Protection 802 441 1 [...]

  • Page 27

    OM-219 316 Page 23 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. T ighten screw . 3 Drive Roll The drive roll consists of two dif fer- ent sized grooves. The stamped markings on the end surface of the drive roll refers [...]

  • Page 28

    OM-219 316 Page 24 7-6. Cleaning Or Replacing Gun Liner Ref. 802 446-A 8 mm / 10mm Y Disconnect gun from unit. T ools Needed: T o Reassemble Gun: Insert new liner . Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out. Hand tighten outlet guide, and then tighten two full turns more. Cut liner of f so that 3/4 in (19 mm) sticks out of[...]

  • Page 29

    OM-219 316 Page 25 7-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Needed: 19 mm Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice an d turn head tube out by hand. Hand-tighten head tube into cable connector . Place head tube in vice and tighten until nuts are tight. Remove from vic[...]

  • Page 30

    OM-219 316 Page 26 7-8. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan does not run Secure power cord plug in receptacle (see Section 5-6). d oes no t run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1). Reset welding power source supplementary protec[...]

  • Page 31

    OM-219 316 Page 27 SECTION 8 − ELECTRICAL DIAGRAM 230 952-A Figure 8-1. Circuit Diagram[...]

  • Page 32

    OM-219 316 Page 28 SECTION 9 − MIG WELDING (GMA W) GUIDELINES 9-1. T ypical MIG Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce w or k c l am p a s close to the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Hose Sh[...]

  • Page 33

    OM-219 316 Page 29 9-2. T ypical MIG Process Control Settings These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. NOTE 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 A 40 − 145 A 50 − 180 [...]

  • Page 34

    OM-219 316 Page 30 9-3. 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. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 Work Clamp 4 Electro[...]

  • Page 35

    OM-219 316 Page 31 9-4. 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. NOTE Slow FILLET WELD ELECTODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PR[...]

  • Page 36

    OM-219 316 Page 32 9-5. 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 . NOTE 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Al[...]

  • Page 37

    OM-219 316 Page 33 9-8. T roubleshooting − 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. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Us[...]

  • Page 38

    OM-219 316 Page 34 9-1 1. T roubleshooting − 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 maintai[...]

  • Page 39

    OM-219 316 Page 35 9-14. T roubleshooting − W aviness Of Bead W aviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding 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 ha[...]

  • Page 40

    OM-219 316 Page 36 9-16. 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. Application Gas Spray Arc Steel Short Circuiting Steel Short Cir[...]

  • Page 41

    OM-219 316 Page 37 Problem Remedy Probable Cause W elding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary . W rong 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 welding power s[...]

  • Page 42

    OM-219 316 Page 38 SECTION 10 − P ARTS LIST . Hardware is common and not available unless listed. 803 716-B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 34 32 31 49 43 48 47 46 45 44 51 50 36 35 42 41 40 38 39 37 30 33 52 53 54 Figure 10-1. Main Assembly[...]

  • Page 43

    OM-219 316 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly Quantity 1 199 566 DOOR, access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 196 006 HINGE, door 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 44

    OM-219 316 Page 40 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly (Continued) Quantity 41 207 079 KNOB, pointer (voltage) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 21 1 338 KNOB, pointer (WFS) 1 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 45

    OM-219 316 Page 41 1 802 447 2 34 5 6 7 9 8 10 11 Figure 10-2. H-10 Gun Quantity Description Part No. 195 957 Item No. Figure 10-2. H-10 Gun 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 226 190 NOZZLE, flux cored slip type 1 . . . . . . .[...]

  • Page 46

    OM-219 316 Page 42 10-3. Optional Drive Rolls For All Feed Head Assemblies P ART NO. WIRE DIAMETER INCHES (mm) 202 925 .023/.025 (.6) and .030/.035 (.8 and .9) 202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove) 10-4. Options P ART NO. DESCRIPTION REMARKS 770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder , 100 lb (45 kg) max. 194 776[...]

  • Page 47

    Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below , warrants to its original retail purchaser that n[...]

  • Page 48

    PRINTED IN USA 1/04 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Please complete and retain with your personal records. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessorie[...]