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OM-234 016D 2007−11
Processes
MIG (GMAW) Welding
Description
Wire Feeder Spool Gun
Spoolmate 100 Series
Visit our website at File: Wire Feeder
www.MillerWelds.com
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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. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation,
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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 Indicates special instructions. 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. The possible This grou
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Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap. health. Remove any combustibles, such as a butane lighter or matches, Keep your head out of the fumes. Do not breathe the
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring − be sure power supply system is Have only qualified persons remove doors, panels, covers, or properly sized,
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1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health & Safety Code Section 25249.5 et seq.) tive harm. For Diesel Engines: Battery posts, terminals and related accessories contain lead and lead
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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 Indique des instructions spécifiques. 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
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Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in- les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. Le soudage effectué sur des conteneurs fermés tels Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peu décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement. Des étincelles peuven indiquées dans la partie Entretien avant de touche
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Protéger les bouteilles de gaz comprimé d’une chaleur excessive, LES ACCUMULATIONS DE GAZ des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. Placer les bouteilles debout en les fixant dans un support station- Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation. de se renverser. Veiller toujours à bien
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LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. Le rayonnement haute fréquence (H.F.) peut Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica- geant le fil de soudage. tion, les services de sécurité et les ordinate
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for We
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OM-234 016 Page 10
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SECTION 3 − INSTALLATION 3-1. Specifications Approximate Wire Cooling Maximum Weld Circuit Wire Diameter Range Overall Dimensions Weight Feed Range Method Spool Size Rating Millermatic 140 AutoSet: 5 To 365 ipm .030 Thru .035 in Length: (0.8 Thru 0.9 mm) (0.13 To 9.27 mpm) 22.5 Volts, 135 13 in (330 mm) Aluminum Wire Millermatic 140: Amperes, 30% Width: Or Flux Cored Wire 5 To 435 ipm 4 in (102 mm) 5.6 lb (2.54 kg) Air Cooled Duty Cycle 2-1/4 in (57 mm) (0.13 To 11.05 mpm) Diameter Gun With Cabl
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3-3. Connecting Spool Gun To Millermatic 140/180 Models A. Installing Optional Spool Gun Switch In Millermatic 140/180 Models 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. 2 1 ! Turn Off unit, and disconnect input power. For units prior to Serial No. LH210051N, use retrokit part no. 300409 for installing spool gun switch. 3 Remove wrapper from welding 1 power source. 1 Welding Power Source Center Baffle 2
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B. Connecting Spool Gun To Millermatic 140/180 1 Drive Assembly 2 Spool Gun 3 Gun Securing Knob 6 7 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 5 shielding gas. 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 6 Spool Gun/MIG Gun Switch Place switch in Spool Gun position. 7 Polarity Changeover Terminal Block To make proper polarit
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3-4. Connecting Spool Gun To Millermatic Passport Plus 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 5 completely to prevent leakage of shielding gas. 5 Gun Trigger Plug 4 Insert plug into receptacle, and tighten threaded collar. 6 Internal/External Transfer Switch Place switch in the External Gas Supply position. 2 7 Polarity Changeover Termin
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3-5. Connecting Spool Gun To Renegade 180 1 Drive Assembly 2 Spool Gun 3 Gun Securing Knob 6 4 Gun End Loosen gun securing knob. Insert end 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 shielding gas leakage. Spool gun must be inserted completely to prevent leakage of shielding gas. 5 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 6 Spool Gun/MIG
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3-6. Installing Wire Spool And Threading Welding Wire 1 Thumb Screw 2 Spool Cover Remove thumb screw and spool Tools Needed: cover. 7 8 6 3 Hub Tension Nut 4 Wire Spool 5 Install spool so wire feeds from top. Turn hub tension nut just so a slight 4 drag is felt on the wire spool. 5 Push Roll/Lower Drive Roll 2 6 Drive Roll Pressure Adjustment Opening 7 Drive Roll Release Lever 1 (Red) 3 8 Wire Inlet Guide 9 9 Contact Tip 10 10 Nozzle Remove nozzle and contact tip. Push Release red lever. and hol
