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Miller Electric OM-234 016D manual

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Table of contents for the manual

  • Page 1

    OM-234 016D 2007−11 Spoolmate 100 Series V isit our website at www.MillerWelds.com Processes Description MIG (GMAW ) W elding Wire Feeder Spool Gun File: Wire Feeder[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • 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

    [...]

  • Page 5

    OM-234 016 Page 1 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 o[...]

  • Page 6

    OM-234 016 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. 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 poo[...]

  • Page 7

    OM-234 016 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-234 016 Page 4 1-4. California Proposition 65 W arnings W elding 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 [...]

  • Page 9

    OM-234 016 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007−04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures grave[...]

  • Page 10

    OM-234 016 Page 6 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 CH[...]

  • Page 11

    OM-234 016 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

  • Page 12

    OM-234 016 Page 8 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 per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de t o ucher[...]

  • Page 13

    OM-234 016 Page 9 2-5. P ri nci pal es n or me s de s écu ri té Safety i n W elding, 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 W elding and Cut- ting of Containers and Piping , American [...]

  • Page 14

    OM-234 016 Page 10[...]

  • Page 15

    OM-234 016 Page 1 1 SECTION 3 − INST ALLA TION 3-1. Specifications Wire Diameter Range Approximate Wire Feed Range Cooling Method Maximum Spool Size W eld Circuit Rating Overall Dimensions W eight .030 Thru .035 in (0.8 Thru 0.9 mm) Aluminum Wire Or Flux Cored Wire .023 Thru 035 in (0.6 Thru 0.9 mm) Solid Wire Millermatic 140 AutoSet: 5 T o 365 i[...]

  • Page 16

    OM-234 016 Page 12 3-3. Connecting Spool Gun T o Millermatic 140/180 Models A. Installing Optional Spool Gun Switch In Millermatic 140/180 Models Ref. 804 984-A / 804 982-A T ools Nee d e d : 1/4, 5/16 in 9/16 in . For Renegade 180 And Passport Plus Models: Discard switch assembly; unit is pre−wired for spool gun option. Go to Section 3-4 or 3-5.[...]

  • Page 17

    OM-234 016 Page 13 B. Connecting Spool Gun T o Millermatic 140/180 804 984-A / Ref. 801 987 1 Drive Assembly 2 Spool Gun 3 Gun Securing Knob 4 Gun End Loosen thumbscrew . Insert end through opening until it bottoms against drive assembly . Tighten gun securing knob. Spool gun must be inserted completely to prevent leakage of shielding gas. 5 Gun Tr[...]

  • Page 18

    OM-234 016 Page 14 3-4. Connecting Spool Gun T o Millermatic Passport Plus 805 095-A / Ref. 801 987 1 Drive Assembly 2 Spool Gun 3 Gun Securing Knob 4 Gun End Loosen thumbscrew . Insert end through opening until it bottoms against drive assembly . Tighten gun securing knob. Spool gun must be inserted completely to prevent leakage of shielding gas. [...]

  • Page 19

    OM-234 016 Page 15 3-5. Connecting Spool Gun T o Renegade 180 804 755-B 1 Drive Assembly 2 Spool Gun 3 Gun Securing Knob 4 Gun End Loosen gun securing knob. Insert en d through opening until it bottoms against drive assembly . Tighten gun securing knob. . Be sure that gun end is tight against drive assembly . Ex- posed O−rings will cause shieldin[...]

  • Page 20

    OM-234 016 Page 16 3-6. Installing Wire Spool And Threading Welding Wire 804 985-A T ools Nee d e d : 1 Thumb Screw 2 Spool Cover Remove thumb screw and spool cover . 3 Hub T ension Nut 4 Wire Spool Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool. 5 Push Roll/Lower Drive Roll 6 Drive Roll P[...]

  • Page 21

    OM-234 016 Page 17 SECTION 4 − OPERA TION 4-1. Controls For Millermatic 140/180 Models A. Spool Gun Operation On Millermatic 140/180 Models sb5.1* 6/92 − S-0621-C / Ref. 802 982-A / 804 986-A . Spool Gun/MIG Gun switch on Millermatic 140/180 must be in Spool Gun position for spool gun to operate. 1 Shielding Gas Cylinder For shielding gas conne[...]

  • Page 22

    OM-234 016 Page 18 B. Weld Parameter Chart For Millermatic 140 Model w/Auto−Set E 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. NOTE: Settings are approximate. Adjust as required. “−−−” Means not recommended. “*” Thicker mater[...]

  • Page 23

    OM-234 016 Page 19 227 931-H H Manual Setup Refer to chart below to select Voltage and Wire Speed based on thickness of metal being welded. 2. Number on left of slash is Voltage Knob Setting. (Example: 4 / 65) 1. Number on right of slash is Wire Speed Knob Setting. (Example: 4 / 65 ) 10/90 10/65 10/80 10/60 10/65 10/50 10/50 10/75 5.5/60 5.5/80 7/8[...]

  • Page 24

    OM-234 016 Page 20 C. Weld Parameter Chart For Millermatic 140 Model w/Factory Set Non-Wire Speed T racking Mode . Color parameter charts can be downloaded from www . MillerWelds.com or by ordering from a Miller distributor. 1. Number on left of slash is Voltage Knob Setting. (Example: 4.5/55) 2. Number on right of slash is W ire Speed Knob Setting[...]

  • Page 25

    OM-234 016 Page 21 224 940-E 3/40 3.5/45 2.5/30 2.5/35 3.5/40 3.5/50 4.5/35 4.5/32 5/50 5/40 5/45 5/35 4/55 4/55 2/30 2.5/25 5.5/60 8/70 8/60 5.5/85 6.5/70 5.5/55 6/40 7/90 7/75 10/95 10/70 10/80 10/65 10/60 8/50 10/55 10/95 10/80 5.5/50 3.5/45 6/45 6/55 4.5/55 4.5/70 4/35 6.5/80 6.5/70 NOTE: Settings are approximate. Adjust as required. ?[...]

  • Page 26

    OM-234 016 Page 22 D. Weld Parameter Chart For Millermatic 180 Model w/Factory Set Non-Wire Speed T racking Mode .030” (0.8 mm) .035” (0.9 mm) 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) .045” (1.2 mm) #000069 .035 − .045” (0.9 − 1.2 [...]

  • Page 27

    OM-234 016 Page 23 225 229-E 225 229−E 1.5/20 2/25 3.5/25 3/15 1/15 2.5/30 3.5/25 3.5/20 3/12 3.5/60 5/60 5.5/35 4/45 4/70 6/100 6/40 7/85 6/55 6/65 6.5/65 6.5/50 6.5/75 10/75 10/55 5.5/45 4.5/50 3.5/35 4.5/30 4.5/35 1.5/15 2/20 2/20 2.5/30 3.5/40 4.5/55 6/75 6/80 10/95 3/35 3.5/45 3.5/30 6/95 5/80 4.5/70 4/50 2/70 10/100 8/95 5/70 4/70 2/70 10/9[...]

  • Page 28

    OM-234 016 Page 24 Notes[...]

  • Page 29

    OM-234 016 Page 25 4-2. Controls For Millermatic Passport Plus Model A. Spool Gun Operation On Millermatic Passport Plus Model sb5.1* 6/92 − S-0621-C / Ref. 235 125-B / Ref. 804 986-A 1 Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual. 2 V alve Open valve on cylinder just before welding. Close valve [...]

  • Page 30

    OM-234 016 Page 26 B. Weld Parameter Chart For Millermatic Passport Plus Model .030”(0.8 mm) .030”(0.8 mm) Min/10 1.5/20 .035”(0.9 mm) .5/10 1.5/15 .030”(0.8 mm) Min/10 2/20 .035”(0.9 mm) Min/5 2/15 .035”(0.9 mm) Aluminum Spool Gun Aluminum 4043ER 100% Argon Steel Stainless Steel Stainless Steel (DCEP) Flux Core E71T−11 (DCEN) Solid W[...]

  • Page 31

    OM-234 016 Page 27 Ref. 235 557-A 3/30 4/40 4.5/45 5.5/50 6.5/50 7/50 8/70 9/65 10/80 3/25 4/30 5/35 6/40 6.5/45 7/45 8.5/55 9/55 10/60 3/35 3.5/40 4/50 5/60 5.5/70 7/60 7.5/80 8/90 9.5/100 3/30 3.5/35 4/40 5/50 5.5/60 7/50 7.5/65 8/75 10/90 2.5/50 3.5/65 4.5/100 3/35 4/50 4.5/55 5.5/65 7/100 2.5/40 3.5/55 4.5/80 5/80 5.5/85 5.5/100 2.5/30 3.5/50 4[...]

  • Page 32

    OM-234 016 Page 28 4-3. Controls For Renegade 180 Model A. Spool Gun Operation On Renegade 180 Model sb5.1* 6/92 − S-0621-C / Ref. 804 755-B / Ref. 804 986-A / 804 476-C . Spool Gun/MIG Gun switch on Renegade 180 must be in Spool Gun position for spool gun to operate. 1 Shielding Gas Cylinder For shielding gas connections, see welding power sourc[...]

  • Page 33

    OM-234 016 Page 29 B. Weld Parameters For Renegade 180 Model Select Wire T ype, Polarity , and Shielding Gas Wire Size Material Thickness Select Wire T ype, Polarity , and Shielding Gas Wire Size 20 ga 18 ga 16 ga 14 ga 1/8 in. 3/16 in. 1/4 in. 5/16 in. Shop Settings (Wall or Premise Power , 230 V 1 Ph) Aluminum 4043 (DCEP) 100% Argon Shielding Gas[...]

  • Page 34

    OM-234 016 Page 30 SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every 3 l Unreadable Labels ~ W eld T erminals l Damaged Gas Hose nl[...]

  • Page 35

    OM-234 016 Page 31 5-2. Changing Drive Rolls 804 987-A T ools Nee d e d : ! T urn Off power at welding power source first. 1 Drive Roll Cover Remove cover . Changing Push Roll: T o remove push roll: 2 Push Roll Screw 3 W asher 4 Push Roll Remove screw and washer , and lift out drive roll. T o install drive roll: Slide drive roll onto shaft and se- [...]

  • Page 36

    OM-234 016 Page 32 5-3. Changing Liner Ref. 804 985-A T ools Nee d e d : ! T urn Off power at welding power source first. 1 Nozzle 2 Contact T ip 3 Liner Remove and replace liner . Reinstall parts as shown. 1 2 3 5-4. T roubleshooting T rouble Remedy No weld output; gun/feeder does not work. Place Power switch on welding power source in the On posi[...]

  • Page 37

    OM-234 016 Page 33 5-5. GMA W (MIG) Aluminum Welding Hints Here are several hints to help you be more successful with your new aluminum feed system. MIG welding aluminum requires dif ferent techniques than MIG welding mild steel. A. Before Y ou Start Welding S The removal of lubricants from the aluminum base material may be necessary . Consult with[...]

  • Page 38

    OM-234 016 Page 34 S Maintain a 3/4 in. (19 mm) tip-to-work distance, and have the contact tip recessed approximately 1/8 in. inside the nozzle if possible. See Figure 5-2. Gas Nozzle Contact Tube Recessed 1/8 in . (3.2 mm) Inside The Nozzle Contact Tip T o Work Distance 3/4 in. (19 mm) Figure 5-2. Contact T ube Position And Tip-T o-Work Distance S[...]

  • Page 39

    OM-234 016 Page 35 SECTION 6 − ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram For Spoolmate 186 451[...]

  • Page 40

    OM-234 016 Page 36 Figure 6-2. Circuit Diagram For Millermatic 140/180[...]

  • Page 41

    OM-234 016 Page 37 234 419-B[...]

  • Page 42

    OM-234 016 Page 38 SECTION 7 − P ARTS LIST . Hardware is common and not available unless listed. 804 988-A 3 2 26 29 27 15 28 25 24 23 18 17 16 13 11 10 4 9 8 7 6 5 4 2 1 39 36 37 38 35 34 32 31 30 19 22 21 20 12 14 33 40 41 42 Figure 7-1. Complete Assembly[...]

  • Page 43

    OM-234 016 Page 39 Quantity Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly 1 PB1 186 416 TRIGGER SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 186 418 PLASTIC HANDLE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 44

    Notes[...]

  • Page 45

    Notes[...]

  • Page 46

    Notes[...]

  • Page 47

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007−01 Y our distributor also gives you ... Service Y ou 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 expert[...]

  • Page 48

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 920-735-4134 Int ernational F A X : 9 20-735-4125 European Headquarters ?[...]