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OM-225 311C 2007−05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
Millermatic 140,
™
140 Auto−Set , And 180
And M-10 Gun
Visit our website at
File: MIG (GMAW)
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 Insta
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TABLE OF CONTENTS SECTION 6 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6-3. Drive Motor Protecti
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 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 necessa
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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 an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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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. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Nationa
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier d’É
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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A complete Parts List is available on-line at www.MillerWelds.com SECTION 3 − SPECIFICATIONS 3-1. Specifications A. 115 VAC Model Amperes Input at Maximum Rated Welding Rated Load Out- Weight Overall Amperage Range Open-Circuit KVA KW Output put 115 V, 60 Hz, W/ Gun Dimensions Voltage DC Single-Phase Length: 17-1/2 in 90 A @ 18 (444 mm) Volts DC, 20% Duty Cycle 20 2.8 2.4 60 lb Width: 10-5/8 in (27 kg) 30 − 140 28 (273 mm) 63 A @ 21 15* 2.1* 1.8* Volts DC, 20% Height: 15-3/4 in Duty Cycle* (4
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A complete Parts List is available on-line at www.MillerWelds.com 3-2. 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) A. 115 VAC opens, output stops, and cooling Model fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Exceeding duty cycle can damage unit or gun and void warranty. 20% duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting B.
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A complete Parts List is available on-line at www.MillerWelds.com 3-3. Volt-Ampere Curves The volt-ampere curves show the A. 115 VAC Model minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the 30 curves shown. 25 20 M AX 15 M IN 10 5 0 0 20406080 100 120 140 160 AM PE R AGE B. 230 VAC Model 30 25 20 MA X 15 MI N 10 5 0 0 2 0 4 0 6 0 8 0 1 00 1 2 0 1 40 1 6 0 180 200 A M PER A G E 225 265-A / 228 250-A OM-225 311 Page
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A complete Parts List is available on-line at www.MillerWelds.com SECTION 4 − INSTALLATION 4-1. Installing Welding Gun 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 into receptacle, and tighten 3 4 threaded collar. Close door. 1 2 Be sure that gun end is tight against drive assembly. 33 Correct Incorrect Ref. 802 982-A / Ref. 801 987 4-2. Installing Work Clamp 1 Nut
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A complete Parts List is available on-line at www.MillerWelds.com 4-3. Work Cable Routing Inside Unit 2 1 Work Cable 2 Output Terminal Block Insert work cable through opening in front panel and route along back of front panel to output terminal block. 1 Close door. Ref. 802 982-A 4-4. Process/Polarity Table Cable Connections Process Process Polarity Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) ou
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A complete Parts List is available on-line at www.MillerWelds.com 4-6. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter 1 Cap with CO shielding gas. See Parts List for optional 2 2 Cylinder Valve CO gas regulator/flowmeter and hose. 2 Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. 1 Close valve
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A complete Parts List is available on-line at www.MillerWelds.com 4-7. Selecting A Location And Connecting Input Power For 115 VAC Model 1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected by time-delay 1 18 in fuses or circuit breaker is required. (460 mm) 3 Plug From Unit 2 Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m). Special installation may be required where gasoline or volatile liquids are present
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A complete Parts List is available on-line at www.MillerWelds.com 4-8. Selecting A Location And Connecting Input Power For 230 VAC Model Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. Disconnect and lockout/tag- out input power before con- Do not move or operate unit necting input conductors from where it could tip. unit. Always connect green or green/yellow conductor to 18 in (457 mm) of 1 supply grounding terminal space for
