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R Processes OM-225 311C 2007−05 Arc W elding Power Source And Wire Feeder Description MIG (GMAW ) W elding Flux Cored (FCA W ) W elding Millermatic 140, 140 Auto− Set , And 180 And M-10 Gun File: MIG (GMA W) V isit our website at www.MillerWelds.com [...]

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[...]

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

T ABLE OF CONTENTS SECTION 6 − MAINTENANCE &TROUBLESHOOTING 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Routine Maintenance 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Overload Protection 36 . . .[...]

OM-225 31 1 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 m[...]

OM-225 31 1 Page 2 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. 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 watching[...]

OM-225 31 1 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[...]

OM-225 31 1 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 [...]

OM-225 31 1 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION 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 ut ilisés Sy m bole graphique d’avertis sement ! Attention ! Cette pro- cédur e c omport e des risques poss ible[...]

OM-225 31 1 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 p[...]

OM-225 31 1 Page 7 2-3 . Dangers s upplémenta ires en r elation ave c l ’installa tion, l e f onctionnement et l a maintenanc e 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[...]

OM-225 31 1 Page 8 2-5. Prin cipales nor mes de sécuri té Safety i n 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 for the Preparation for W elding and Cut- ting of Containers and Piping , American W el[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 9 SECTION 3 − SPECIFICA TIONS 3-1. Specifications A. 1 15 V AC Model Rated Welding Output Amperage Range Maximum Open-Circuit V oltage DC Amperes Input at Rated Load Out- put 1 15 V , 60 Hz, Single-Phase KV A KW W eight W/ Gun Overall Dimensions 90 A @ 18 V olt[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 10 3-2. Duty Cycle And Overheating Duty Cy cle is percenta ge of 10 minutes t hat unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. W ait fifteen minutes for unit to cool. Reduce amperage [...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 1 1 3-3. 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. 225 265-A / 228 250-A A. 1 15 V AC Model B. 230 V AC Mo[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 12 SECTION 4 − INST ALLA TION 4-1. Installing Welding Gun Ref. 802 982-A / Ref. 801 987 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob. Insert gun end through opening until it bottoms against drive assembly . Tighten knob. 4 Gun Trigger Plug Insert [...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 13 4-3. W ork Cable Routing Inside Unit Ref. 802 982-A 1 Work Cable 2 Output T erminal Block Insert work cable through opening in front panel and route along back of front panel to output terminal block. Close door . 2 1 4-4. Process/Polarity T able Process Polar[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 14 4-6. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove c ap, stand to side of valve, and open valve slightly . Gas flow blows dus[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 15 4-7. Selecting A Location And Connecting Input Power For 1 15 V AC Model 1 Rating Label 2 Grounded Receptacle A 1 15 volt, 20 ampere i ndividual branc h c ir cuit protect ed b y t ime-delay fuses or circ uit br eaker is required. 3 Plug From Unit Select extens[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 16 4-8. Selecting A Location And Connecting Input Power For 230 V AC Model Y Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. Y Disconnect and lockout/tag- out input power before con- necting input cond[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 17 4-9. Electrical Service Guide For 230 V AC Model 60 Hz Single Phase Input V oltage 230 Input Amperes At Rated Output 21.7 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 , Time-Delay 2 25 Normal Operating 3 30 Min Input Conductor Size In A WG[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 18 4-1 1. 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: 6 1 3 4 5 Pull and hold wire; cut off end. 4 in (102 mm) Remove gun nozzle and c[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 19 4-12. Removing MIG Gun From Welding Power Source Open Pressure Assembly . Hold wire tightly to keep it from unr aveling. Rewind Wire Onto Spool, Fasten End Of Wire T o Spool Cut Off End Of Wire Loosen Knob, Disconnect Gun T rigger Plug, And Pull Gun From Unit [...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 20 4-13. Installing Optional Spool Gun Switch In Welding Power Source Ref. 804 984-A / 804 892-A T ools Nee d e d : 1/4, 5/16 in 9/16 in Y T ur n Off unit, and disconnect input power . . For units prior to Serial No. LH210051N, use retrokit part no. 234402 for in[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 21 4-14. 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[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 22 SECTION 5 − O P E R A T I O N 5-1. Controls For 1 15 V AC Model w/Auto-Set E 1 Wire Speed Control T urn control clockwise inside white scale (10-100) t o increase wire feed speed. (see weld parameter chart in welding power source o r Section 5-4, 5-5, 5 -6 ,[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 23 5-2. Controls For 1 15 V AC Model 1 Wire Speed Control T urn control clockwise to increase wire feed speed. (see weld parameter chart in welding power source or Section 5-4 , 5-5, 5-6, 5-7, or 5-8, as applicable). 2 V oltage Control T urn control clockwise to [...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 24 5-3. Controls For 230 V AC Model 1 Wire Speed Control T urn control clockwise to increase wire feed speed. (see weld parameter chart in welding power source or Section 5 -5, 5-4, 5-6, 5-7 or 5-8, as applicable). 2 V oltage Control T urn control clockwise to in[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 25 Notes[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 26 5-4. W eld Parameter Chart For 1 15 V AC 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 re[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 27 227 931-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 /[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 28 5-5. W eld Parameter Chart For 1 15 V AC Model w/Factory Set Non-Wire Speed T racking Mode 1. Number on left of slash is Voltage Knob Setting. (Example: 4.5 / 65) 2. Number on right of slash is Wire Speed Knob Setting. (Example: 4.5 / 65) Refer to chart below [...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 29 224 940-D 3/30 3.5/45 2.5/28 2.5/35 3/30 3.5/45 4.5/35 5/22 5/40 5/30 5.5/45 5.5/30 4.5/40 4/55 2/30 2/25 6/50 8/65 6.5/40 5.5/80 5.5/50 5.5/50 6/40 7.5/85 7/70 10/90 10/45 10/60 10/30 10/45 8/40 10/32 10/80 10/60 5/35 3.5/40 6/35 5.5/55 5/45 4.5/65 3.5/25 6.5[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 30 5-6. W eld Parameter Chart For 1 15 V AC Model w/Wire Speed T racking Mode 1. Number on left of slash is Voltage Knob Setting. (Example: 4.5/65) 2. Number on right of slash is Wire Speed Knob Setting. (Example: 4.5 / 65) Refer to chart below to select Voltage [...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 31 232 016-A 3/30 3.5/45 2.5/28 2.5/35 3/30 3.5/45 4.5/35 5/22 5/40 5/30 5.5/45 5.5/30 4.5/40 4/55 2/30 2/25 6/50 8/65 6.5/40 5.5/80 5.5/50 5.5/50 6/40 7.5/85 7/70 10/90 10/45 10/60 10/30 10/45 8/40 10/32 10/80 10/60 5/35 3.5/40 6/35 5.5/55 5/45 4.5/65 3.5/25 6.5[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 32 5-7. W eld Parameter Chart For 230 V AC 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[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 33 225 229-F 225 229−F 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[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 34 5-8. W eld Parameter Chart For 230 V AC Model w/Wire Speed T racking Mode 1. Number on left of slash is Voltage Knob Setting. (Example: 4.5 / 65) 2. Number on right of slash is Wire Speed Knob Setting. (Example: 4.5 / 65) .045” (1.2 mm) #000069 .035 − .045[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 35 232 017-A 232 017-A 2.5/10 2/22 2.5/15 2.5/15 3/20 2.5/28 2.5/15 3.5/20 3.5/10 3.5/30 1/15 1/15 3/30 3.5/20 3.5/25 4/10 4/10 4/40 4/20 4/25 4/10 3.5/15 4.5/40 4/50 5/50 5/50 5/25 4/40 4/35 4/20 4.5/70 4.5/35 5.5/60 7/100 6/50 6/25 6/45 6/30 5.5/65 6.5/40 5.5/5[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 36 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y 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 Referenc[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 37 6-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Remove guide by pressing on barbed area or cutting of f one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place. 2 Drive Roll The drive roll con[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 38 6-6. Cleaning Or Replacing Gun Liner Ref. ST-802 399-A 8 mm / 10 mm Y Disconnect gun from unit. T ools Needed: Lay gun cable out straight before installing new liner . Head Tube 8 mm Remove liner . Remove nozzle, contact tip, adapter , gas dif fuser , and wire[...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 39 6-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Nee d e d : 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 [...]

. A complete Parts List is available on-line at www .MillerW elds.com OM-225 31 1 Page 40 6-8. 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 4-7 or 4-8). does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in O[...]

OM-225 31 1 Page 41 Notes[...]

OM-225 31 1 Page 42 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram[...]

OM-225 31 1 Page 43 234 419-B[...]

OM-225 31 1 Page 44 SECTION 8 − MIG WELDING (GMA W) GUIDELINES 8-1. 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 c e w o r k c l a m p a s close t o the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Ho[...]

OM-225 31 1 Page 45 8-2. 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 1/8 or .125 in Material thickness determines weld parameters. Convert Material (.001 in = 1 ampere)[...]

OM-225 31 1 Page 46 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. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 Work Clamp 4 Electr[...]

OM-225 31 1 Page 47 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. NOTE Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS (ST[...]

OM-225 31 1 Page 48 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 . NOTE 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement A[...]

OM-225 31 1 Page 49 8-8. T roubleshooting − Excessive Spatter Excessive Spa tter − scattering of molten metal partic les that cool t o 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[...]

OM-225 31 1 Page 50 8-10. T roubleshooting − Excessive Penetration Good Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration S-0639 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase travel speed. W rong [...]

OM-225 31 1 Page 51 8-13. T roubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting i n 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. W rong polarity[...]

OM-225 31 1 Page 52 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. Application Gas Spray Arc Steel Short Circuiting Steel Short Ci[...]

OM-225 31 1 Page 53 SECTION 9 − P ARTS LIST 9-1. Recommended Spare Parts Quanti ty Description Part No. Item No. 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ♦ 087 299 TIP , contact scr .023 wire x 1.125 . . . . . . . . . . . . . . . . [...]

Notes[...]

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[...]

PRINTED IN USA  2007 Miller Electric Mfg. Co. 2007−01 Miller Elect ric Mfg. Co. An I l li noi s T ool Works 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 AX : 9 20-735-4125 European Headquarter s ?[...]