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OM-1215 199 381
March 2000
Processes
MIG (GMAW) Welding
Description
Wire Feeder Spool Gun
Spoolmate 250
Visit our website at
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, Operation, And Maintenance . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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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 properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – INSTALLATION 2-1. Specifications Approximate Cooling Maximum Spool Weld Circuit Overall Wire Diameter Range Wire Feed Weight Method Size Rating Dimensions Range .030 Thru .047 in Length: (0.8 Thru 1.2 mm) 100 Volts, 200 11-1/2 in (291 mm) Aluminum Wire 130 To 840 ipm Amperes, 60% Width: 4 in (102 mm) 9.1 lb (4.1 kg) (4.1 To 20.4 Air Cooled Duty Cycle 2-1/4 in (57 mm) Diameter Gun With Cable .030 Thru 047 in mpm) Using Argon (0.8 Thru 1.2 mm) Height: Shielding Gas Hard Or Cored Wire 8
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2-3. Connecting Spoolgun To Welding Power Source 5 5 2 4 3 7 6 1 6 Tools Needed: 8 Ref. 802 582 3/4 in Turn Off unit. negative (–) output terminal. put barbed end of diverter valve into hose. Secure with hose clamp. 5 Existing Gas Hose Disconnect and remove MIG (GMAW) welding gun, if applicable. Slide hose clamp down gas hose from gun, 6 Spoolgun Gas Hose and cut barbed fitting off hose. Route gas 1 Front Panel Opening 7 Gas Diverter Valve hose through front panel opening, and 2 Spoolgun Weld
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2-4. Installing Wire Spool And Threading Welding Wire 1 Thumb Screw 2 Spool Cover Remove thumb screw and spool Tools Needed: cover. 7 6 8 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
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SECTION 3 – OPERATION 3-1. Controls Spoolgun On/Off switch in welding power source must be in On position for spoolgun operation (see Section 2-2). 1 Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual. 2 Valve Open valve on cylinder just before 2 welding. 3 Trigger 1 Press trigger to energize welding power source contactor, start shielding gas flow, and begin wire feed. Wire feed speed is controlled by welding power source Wire Speed control (see Secti
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4-2. Changing Drive Rolls Turn Off power at welding power source first. 1 Drive Roll Cover Remove cover. Changing Push Roll: To remove push roll: 2 Push Roll Screw 3 Washer 4 Push Roll 5 Bearing Remove screw and washer, and lift out push roll. To install push roll: 5 4 Slide push roll onto bearing and 3 shaft, and secure with washer and 2 screw. It may be necessary to remove 1 Changing Lower Drive Roll: drive roll side of gun case to change lower drive roll. To remove drive roll: 6 Lower Drive
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4-3. Changing Liner Turn Off power at welding power source first. 1 Nozzle 2 Contact Tip 3 Liner Remove and replace liner. Reinstall parts as shown. 3 2 1 Tools Needed: Ref. 802 576 4-4. Troubleshooting Trouble Remedy Gun tube assembly loose. Tighten nut at base of gun tube assembly. No weld output; gun/feeder does not Place Power switch on welding power source in the On position (see welding power source Owner’s work. Manual). Erratic weld output. Tighten and clean all connections. Pressing g
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SECTION 5 – ELECTRICAL DIAGRAMS SA-186 451 Figure 5-1. Circuit Diagram OM-1215 Page 15
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SECTION 6 – PARTS LIST Hardware is common and not available unless listed. 802 577 Figure 6-1. Complete Assembly OM-1215 Page 16
