o230693b_mil

8/7/2019 o230693b_mil

1/52

Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Arc Welding Power Sourceand Wire Feeder

OM-230 693B 200707

Millermatic 252R

File: MIG (GMAW)Visit our website atwww.MillerWelds.com

8/7/2019 o230693b_mil

2/52

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. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. We know you dont have time to do

it any other way.

Thats 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 couldnt 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 build and sell Miller products continue the

tradition. Theyre just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

Weve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

theres a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer inthe U.S.A. to be registered tothe ISO 9001:2000 QualitySystem Standard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Mil_Thank 4/05

8/7/2019 o230693b_mil

3/52

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 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. California Proposition 65 Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Symboles utiliss 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 7. . . . . .2-4. Proposition californienne 65 Avertissements 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6. Information EMF 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Symbols And Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Welding Power Source Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Volt-Ampere Curves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4. Connecting To Weld Output Terminals 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5. Installing Work Cable And Clamp 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6. Connecting Spoolmatic) 15A Or 30A Gun 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Setting Gun Polarity For Wire Type 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9. Installing Gas Supply 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10. Installing Wire Spool And Adjusting Hub Tension 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11. Positioning Jumper Links 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12. Electrical Service Guide 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. Selecting A Location And Connecting Input Power 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14. Threading Welding Wire 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15. Weld Parameters 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Controls 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Voltmeter And Wire Feed Speed Meter Operation 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Jog Mode 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Timers 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Set Up Push Motor Torque (SUP) Or Reset (rES) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 MAINTENANCE &TROUBLESHOOTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Routine Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Unit Overload 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Changing Drive Roll and Wire Inlet Guide 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Aligning Drive Rolls and Wire Guide 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Troubleshooting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 7 ELECTRICAL DIAGRAM 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8/7/2019 o230693b_mil

4/52

TABLE OF CONTENTS

SECTION 8 MIG WELDING (GMAW) GUIDELINES 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1. Typical MIG Process Connections 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2. Typical MIG Process Control Settings 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Holding And Positioning Welding Gun 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4. Conditions That Affect Weld Bead Shape 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Gun Movement During Welding 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6. Poor Weld Bead Characteristics 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7. Good Weld Bead Characteristics 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8. Troubleshooting Excessive Spatter 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9. Troubleshooting Porosity 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10. Troubleshooting Excessive Penetration 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11. Troubleshooting Lack Of Penetration 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12. Troubleshooting Incomplete Fusion 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13. Troubleshooting Burn-Through 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-14. Troubleshooting Waviness Of Bead 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15. Troubleshooting Distortion 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-16. Common MIG Shielding Gases 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17. Troubleshooting Guide For Semiautomatic Welding Equipment 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 PARTS LIST 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

8/7/2019 o230693b_mil

5/52

OM-230 693 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05

Y Warning: Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

Y Marks a special safety message.

. Means Note; not safety related.

This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual tocall attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-5. Read and follow allSafety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

D Do not touch live electrical parts.D Wear dry, hole-free insulating gloves and body protection.D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the workor ground.D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.D Use AC output ONLY if required for the welding process.D If AC output is required, use remote output control if present on

unit.D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

D Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

D When making input connections, attach proper grounding conduc-tor first double-check connections.

D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

D Turn off all equipment when not in use.D Do not use worn, damaged, undersized, or poorly spliced cables.D Do not drape cables over your body.D If earth grounding of the workpiece is required, ground it directly

with a separate cable.D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-chines at the same time since double open-circuit voltage will bepresent.

D Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.D Keep all panels and covers securely in place.D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-typewelding power sources after removal of inputpower.D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

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 poor, wear an approved air-supplied respirator.

D Read and understand the Material Safety Data Sheets (MSDSs)and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

8/7/2019 o230693b_mil

6/52

OM-230 693 Page 2

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

ARC RAYS 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(see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under yourhelmet.

D Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-rial (leather, heavy cotton, or wool) and foot protection.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.D Do not weld where flying sparks can strike flammable material.

D Protect yourself and others from flying sparks and hot metal.

D Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition cancause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and fire

hazards.D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,they can throw off slag.D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun ortorch.D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.D Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.Noise from some processes or equipment candamage hearing.

D Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-tings designed for the specific application; maintain them andassociated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is inuse or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.

8/7/2019 o230693b_mil

7/52

OM-230 693 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 nearcombustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift andsupport unit.

D If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.D Reduce current or reduce duty cycle before

starting to weld again.D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handlingboards or parts.

D Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to doso.

D Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.D Keep all doors, panels, covers, and guards

closed and securely in place.D Have only qualified persons remove doors,

panels, covers, or guards for maintenance asnecessary.

D Reinstall doors, panels, covers, or guardswhen maintenance is finished and before re-connecting input power.

READ INSTRUCTIONS.

D Read Owners Manual before using or servic-ing unit.

D Use only genuine Miller/Hobart replacementparts.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

D Have only qualified persons familiar withelectronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

D If notified by the FCC about interference, stop using theequipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

D Be sure all equipment in the welding area iselectromagnetically compatible.

D To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-tronic equipment.

D Be sure this welding machine is installed and groundedaccording to this manual.

D If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases whichcontain chemicals known to the State of California to causebirth defects and, in some cases, cancer. (California Health &Safety Code Section 25249.5 et seq.)

Y Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

For Gasoline Engines:Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductiveharm.

For Diesel Engines:Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, andother reproductive harm.

8/7/2019 o230693b_mil

8/52

OM-230 693 Page 4

1-5. Principal Safety Standards

Safety in Welding, 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 Welding and Cut-ting of Containers and Piping, American Welding Society StandardAWS F4.1 from Global Engineering Documents (phone:1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA022699101 (phone: 6177703000, website: www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1735 Jefferson Davis Highway,Suite 1004, Arlington, VA 222024102 (phone: 7034120900, web-site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:8004636727or in Toronto 4167474044, website: www.csain-ternational.org).

Practice For Occupational And Educational Eye And Face Protection,ANSI Standard Z87.1, from American National Standards Institute, 11West 42nd Street, New York, NY 100368002 (phone: 2126424900,website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, from National Fire Protection Association,P.O. Box 9101, 1 Battery March Park, Quincy, MA 022699101 (phone:6177703000,website: www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (thereare 10 Regional Officesphone for Region 5, Chicago, is3123532220,website: www.osha.gov).

1-6. EMF Information

Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-ble.

About Pacemakers:Pacemaker wearers consult your doctor before welding or going nearwelding operations. If cleared by your doctor, then following the aboveprocedures is recommended.

8/7/2019 o230693b_mil

9/52

OM-230 693 Page 5

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATIONfre_som _3/05

Y Avertissement : se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Symboles utiliss

Symbole graphique davertissement ! Attention ! Cette pro-cdure comporte des risques possibles ! Les dangers ven-tuels sont reprsents par les symboles graphiques joints.

Y Indique un message de scurit particulier

. Signifie NOTE ; nest pas relatif la scurit.

Ce groupe de symboles signifie Avertissement ! Attention ! RisquesdLECTROCUTION, ORGANES MOBILES et PARTIESCHAUDES. Consulter les symboles et les instructions affrentesci-dessous concernant les mesures prendre pour supprimerles dangers.

2-2. Dangers relatifs au soudage larc

Y Les symboles reprsents ci-dessous sont utiliss dans ce manuelpour attirer lattention et identifier les dangers possibles. Enprsence de lun de ces symboles, prendre garde et suivre lesinstructions affrentes pour viter tout risque. Les instructions enmatire de scurit indiques ci-dessous ne constituent quunsommaire des instructions de scurit plus compltes fourniesdans les normes de scurit numres dans la Section 2-5. Lire etobserver toutes les normes de scurit.

Y Seul un personnel qualifi est autoris installer, faire fonction-ner, entretenir et rparer cet appareil.

Y Pendant le fonctionnement, maintenir distance toutes les per-sonnes, notamment les enfants de lappareil.

UNE DCHARGE LECTRIQUE peutentraner la mort.Le contact dorganes lectriques sous tension peutprovoquer des accidents mortels ou des brluresgraves. Le circuit de llectrode et de la pice estsous tension lorsque le courant est dlivr la

sortie. Le circuit dalimentation et les circuits internes de la machinesont galement sous tension lorsque lalimentation est sur Marche.Dans le mode de soudage avec du fil, le fil, le drouleur, le bloc decommande du rouleau et toutes les parties mtalliques en contactavec le fil sont sous tension lectrique. Un quipement install ou mis la terre de manire incorrecte ou impropre constitue un danger.

D Ne pas toucher aux pices lectriques sous tension.D Porter des gants isolants et des vtements de protection secs et sans

trous.D Sisoler de la pice couper et du sol en utilisant des housses ou destapis assez grands afin dviter tout contact physique avec la pice couper ou le sol.

D Ne pas se servir de source lectrique courant lectrique dans les zo-nes humides, dans les endroits confins ou l o on risque de tomber.

D Se servir dune source lectrique courant lectrique UNIQUEMENT sile procd de soudage le demande.

D Si lutilisation dune source lectrique courant lectrique savre n-cessaire, se servir de la fonction de tlcommande si lappareil en estquip.

D Dautres consignes de scurit sont ncessaires dans les conditionssuivantes : risques lectriques dans un environnement humide ou si lonporte des vtements mouills ; sur des structures mtalliques telles quesols, grilles ou chafaudages ; en position coince comme assise, ge-noux ou couche ; ou sil y a un risque lev de contact invitable ouaccidentel avec la pice souder ou le sol. Dans ces conditions, utiliserles quipements suivants, dans lordre indiqu : 1) un poste souder DC

tension constante ( fil), 2) un poste souder DC manuel (lectrode)ou 3) un poste souder AC tension vide rduite. Dans la plupart dessituations, lutilisation dun poste souder DC fil tension constanteest recommande. En outre, ne pas travailler seul !

D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes descurit).

D Installer le poste correctement et le mettre la terre convenablementselon les consignes du manuel de loprateur et les normes nationales,provinciales et locales.

D Toujours vrifier la terre du cordon dalimentation. Vrifier et sassurerque le fil de terre du cordon dalimentation est bien raccord la bornede terre du sectionneur ou que la fiche du cordon est raccorde uneprise correctement mise la terre.

D En effectuant les raccordements dentre, fixer dabord le conducteurde mise la terre appropri et contre-vrifier les connexions.

D Vrifier frquemment le cordon dalimentation afin de sassurer quilnest pas altr ou nu, le remplacer immdiatement sil lest. Un fil nupeut entraner la mort.

D Lquipement doit tre hors tension lorsquil nest pas utilis.D Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante

ou mal pisss.D Ne pas enrouler les cbles autour du corps.D Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct.D Ne pas toucher llectrode quand on est en contact avec la pice, la terre

ou une lectrode provenant dune autre machine.D Ne pas toucher des porte lectrodes connects deux machines enmme temps cause de la prsence dune tension vide double.

D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel.

D Porter un harnais de scurit si lon doit travailler au-dessus du sol.D Sassurer que tous les panneaux et couvercles sont correctement en

place.D Fixer le cble de retour de faon obtenir un bon contact mtal-mtal

avec la pice souder ou la table de travail, le plus prs possible de lasoudure.

D Isoler la pince de masse quand pas mis la pice pour viter le contactavec tout objet mtallique.

D Ne pas raccorder plus dune lectrode ou plus dun cble de masse une mme borne de sortie de soudage.

Il reste une TENSION DC NON NGLIGEABLE dansles sources de soudage onduleur quand on a couplalimentation.D Arrter les convertisseurs, dbrancher le courant lectrique et

dcharger les condensateurs dalimentation selon les instructions indi-ques dans la partie Entretien avant de toucher les pices.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereuse pour la sant.

LES FUMES ET LES GAZ peuventtre dangereux.

D Ne pas mettre sa tte au-dessus des vapeurs. Ne pas respirer ces va-peurs.

D lintrieur, ventiler la zone et/ou utiliser une ventilation force au niveau delarc pour lvacuation des fumes et des gaz de soudage.

D Si la ventilation est mdiocre, porter un respirateur anti-vapeurs approu-v.

D Lire et comprendre les spcifications de scurit des matriaux (MSDS) etles instructions du fabricant concernant les mtaux, les consommables, lesrevtements, les nettoyants et les dgraisseurs.

D Travailler dans un espace ferm seulement sil est bien ventil ou enportant un respirateur alimentation dair. Demander toujours un sur-veillant dment form de se tenir proximit. Des fumes et des gaz desoudage peuvent dplacer lair et abaisser le niveau doxygne provo-quant des blessures ou des accidents mortels. Sassurer que lair derespiration ne prsente aucun danger.

D Ne pas souder dans des endroits situs proximit doprations de d-graissage, de nettoyage ou de pulvrisation. La chaleur et les rayons delarc peuvent ragir en prsence de vapeurs et former des gaz haute-ment toxiques et irritants.

D Ne pas souder des mtaux munis dun revtement, tels que lacier gal-vanis, plaqu en plomb ou au cadmium moins que le revtement naitt enlev dans la zone de soudure, que lendroit soit bien ventil et enportant un respirateur alimentation dair. Les revtements et tous lesmtaux renfermant ces lments peuvent dgager des fumes toxi-ques en cas de soudage.

8/7/2019 o230693b_mil

10/52

OM-230 693 Page 6

Le rayonnement de larc du procd de soudagegnre des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provo-quer des brlures dans les yeux et sur la peau.

Des tincelles sont projetes pendant le soudage.

LES RAYONS DARC peuvent entra-ner des brlures aux yeux et la peau.

D Porter un casque de soudage approuv muni de verres filtrants ap-propri pour protger visage et yeux pendant le soudage (voir ANSIZ49.1 et Z87.1 numr dans les normes de scurit).

D Porter des lunettes de scurit avec crans latraux mme sous vo-tre casque.

D Avoir recours des crans protecteurs ou des rideaux pourprotger les autres contre les rayonnements les blouissements etles tincelles ; prvenir toute personne sur les lieux de ne pasregarder larc.

D Porter des vtements confectionns avec des matires rsistanteset ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuventtre projetes de larc de soudure. La projection

dtincelles, des pices chaudes et des quipements chauds peuventprovoquer des incendies et des brlures. Le contact accidentel dellectrode avec des objets mtalliques peut provoquer des tincelles,une explosion, une surchauffe ou un incendie. Avant de commencerle soudage, vrifier et sassurer que lendroit ne prsente pas dedanger.

LE SOUDAGE peut provoquer unincendie ou une explosion.

D Dplacer toutes les substances inflammables une distance de10,7 m de larc de soudage. En cas dimpossibilit, les recouvrir soi-gneusement avec des protections homologues.

D Ne pas souder dans un endroit o des tincelles peuvent tomber surdes substances inflammables.

D Se protger, ainsi que toute autre personne travaillant sur les lieux,contre les tincelles et le mtal chaud.

D Des tincelles et des matriaux chauds du soudage peuventfacilement passer dans dautres zones en traversant de petitesfissures et des ouvertures.

D Afin dliminer tout risque de feu, tre vigilant et garder toujours unextincteur la porte de main.

D Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

D Ne pas effectuer le soudage sur des conteneurs ferms tels que desrservoirs, tambours, ou conduites, moins quils naient t prpa-

rs correctement conformment AWS F4.1 (voir les normes descurit).D Brancher le cble de masse sur la pice le plus prs possible de la

zone de soudage pour viter le transport du courant sur une longuedistance par des chemins inconnus ventuels en provoquant desrisques dlectrocution, dtincelles et dincendie.

D Ne pas utiliser le poste de soudage pour dgeler des conduitesgeles.

D En cas de non-utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

D Porter des vtements de protection exempts dhuile tels que desgants en cuir, une veste rsistante, des pantalons sans revers, desbottes et un casque.

D Avant de souder, retirer toute substance combustible de ses pochestelles quun allumeur au butane ou des allumettes.

D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51Bpour travaux de soudage et prvoir un dtecteur dincendie et un ex-tincteur proximit.

DES PARTICULES VOLANTESpeuvent blesser les yeux.D Le soudage, lcaillement, le passage de la

pice la brosse en fil de fer, et le meulagegnrent des tincelles et des particulesmtalliques volantes. Pendant la priode derefroidissement des soudures, elles risquentde projeter du laitier.

D Porter des lunettes de scurit avec crans latraux ou un cranfacial.

LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou mme la mort.D Fermer lalimentation du gaz protecteur en cas

de non-utilisation.D Veiller toujours bien arer les espaces confi-

ns ou se servir dun respirateur dadductiondair homologu.

DES PICES CHAUDES peuvent

provoquer des brlures graves.D Ne pas toucher des parties chaudes mainsnues.

D Prvoir une priode de refroidissement avantdutiliser le pistolet ou la torche.

D Ne pas toucher aux pices chaudes, utiliser les outils recom-mands et porter des gants de soudage et des vtements paispour viter les brlures.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.D Porteurs de stimulateur cardiaque, rester

distance.D Les porteurs dun stimulateur cardiaque doi-

vent dabord consulter leur mdecin avant desapprocher des oprations de soudage larc,de gougeage ou de soudage par points.

LE BRUIT peut endommager loue.Le bruit des processus et des quipements peutaffecter loue.

D Porter des protections approuves pour lesoreilles si le niveau sonore est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endomma-ge, elle peut exploser. Du fait que les bouteilles degaz font normalement partie du procd de soudage,les manipuler avec prcaution.

D Protger les bouteilles de gaz comprim dune chaleur excessi-ve, des chocs mcaniques, des dommages physiques, du lai-tier, des flammes ouvertes, des tincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support sta-tionnaire ou dans un porte-bouteilles pour les empcher de tom-ber ou de se renverser.

D Tenir les bouteilles loignes des circuits de soudage ou autrescircuits lectriques.

D Ne jamais placer une torche de soudage sur une bouteille gaz.D Une lectrode de soudage ne doit jamais entrer en contact avec

une bouteille.D Ne jamais souder une bouteille pressurise risque dexplosion.D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,

tuyaux et raccords convenables pour cette application spcifi-que ; les maintenir ainsi que les lments associs en bon tat.

DDtourner votre visage du dtendeur-rgulateur lorsque vousouvrez la soupape de la bouteille.

D Le couvercle du dtendeur doit toujours tre en place, sauf lors-que la bouteille est utilise ou quelle est relie pour usage ult-rieur.

D Utiliser les quipements corrects, les bonnes procdures et suf-fisamment de personnes pour soulever et dplacer les bouteil-les.

D Lire et suivre les instructions sur les bouteilles de gaz comprim,lquipement connexe et le dpliant P-1 de la CGA (CompressedGas Association) mentionn dans les principales normes de scuri-t.

LES BOUTEILLES peuvent explosersi elles sont endommages.

8/7/2019 o230693b_mil

11/52

OM-230 693 Page 7

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OU DEXPLO-SION.D Ne pas placer lappareil sur, au-dessus ou

proximit de surfaces inflammables.D Ne pas installer lappareil proximit de

produits inflammables.D Ne pas surcharger linstallation lectrique sassurer que

lalimentationest correctement dimensionne et protge avantde mettre lappareil en service.

LA CHUTE DE LAPPAREIL peutblesser.D Utiliser lanneau de levage uniquement pour

soulever lappareil, NON PAS les chariots, lesbouteilles de gaz ou tout autre accessoire.

D Utiliser un quipement de levage de capacitsuffisante pour lever lappareil.

D En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

LEMPLOI EXCESSIF peut SUR-CHAUFFER LQUIPEMENT.D Prvoir une priode de refroidissement ;

respecter le cycle opratoire nominal.D Rduire le courant ou le facteur de marche

avant de poursuivre le soudage.D Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATIQUESpeuvent endommager les circuitsimprims.D tablir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pices.D Utiliser des pochettes et des botes antistati-

ques pour stocker, dplacer ou expdier descartes PC.

DES ORGANES MOBILES peuventprovoquer des blessures.D Ne pas sapprocher des organes mobiles.D Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures.D Ne pas appuyer sur la gchette avant den

avoir reu linstruction.D Ne pas diriger le pistolet vers soi, dautres

personnes ou toute pice mcanique en enga-geant le fil de soudage.

DES ORGANES MOBILES peuventprovoquer des blessures.D Sabstenir de toucher des organes mobiles tels

que des ventilateurs.D Maintenir ferms et verrouills les portes,

panneaux, recouvrements et dispositifs deprotection.

D Seules des personnes qualifies sont autorises enlever les

portes, panneaux, recouvrements ou dispositifs de protectionpour lentretien.D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

LIRE LES INSTRUCTIONS.D Lire le manuel dutilisation avant dutiliser ou

dintervenir sur lappareil.D Utiliser uniquement des pices de rechange

Miller/Hobart.

LE RAYONNEMENT HAUTEFRQUENCE (HF) risque de provoquerdes interfrences.

D Le rayonnement haute frquence (HF) peutprovoquer des interfrences avec les quipe-ments de radio-navigation et de communica-tion, les services de scurit et les ordinateurs.

D Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstal-lation.

D Lutilisateur est tenu de faire corriger rapidement par un lectri-cien qualifi les interfrences rsultant de linstallation.

D Si le FCC signale des interfrences, arrter immdiatementlappareil.

D Effectuer rgulirement le contrle et lentretien de linstallation.D Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs unedistance correcte et utiliser une terre et un blindage pour rduireles interfrences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences.D Lnergie lectromagntique peut gner le

fonctionnement dappareils lectroniquescomme des ordinateurs et des robots.

D Veiller ce que tout lquipement de la zone desoudage soit compatible lectromagntiquement.

D Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poseraussi bas que possible (ex. par terre).

D Veiller souder une distance de 100 mtres de tout quipe-ment lectronique sensible.

D Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

D En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation decbles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Y Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiques dontltat de Californie reconnat quils provoquent des malformationscongnitales et, dans certains cas, des cancers. (Code de sant etde scurit de Californie, chapitre 25249.5 et suivants)

Y Les batteries, les bornes et autres accessoires contiennent duplomb et des composs base de plomb, produits chimiquesdont ltat de Californie reconnat quils provoquent des can-cers et des malformations congnitales ou autres problmes deprocration. Se laver les mains aprs manipulation.

Pour les moteurs essence :Y Les gaz dchappement des moteurs contiennent des produits

chimiques dont ltat de Californie reconnat quils provoquentdes cancers et des malformations congnitales ou autres pro-blmes de procration.

Pour les moteurs diesel :Y Les gaz dchappement des moteurs diesel et certains de leurs

composants sont reconnus par ltat de Californie commeprovoquant des cancers et des malformations congnitales ou au-tres problmes de procration.

8/7/2019 o230693b_mil

12/52

8/7/2019 o230693b_mil

13/52

. A complete Parts List is available at www.MillerWelds.com

OM-230 693 Page 9

SECTION 3 DEFINITIONS

3-1. Symbols And Definitions

Wire Feed Output X Duty Cycle Do Not SwitchWhile WeldingV Volts Increase On Off

Gas Metal ArcWelding (GMAW)

Gun

Wire Feed SpoolGun Gas Input Gas Output

Voltage Input Press To Reset U0 Rated No-LoadVoltage (Average)

SECTION 4 INSTALLATION

4-1. Specifications

Amps Input at Rated Output (60% Duty Cycle), 60 Hz, Single-Phase

Rated Output Max. OpenCircuitVoltage 200 (208) V 230 V 460 V 575 V KVA KW

250 A at 28 VDC,40% Duty Cycle

200 A at 28 VDC,60% Duty Cycle

38 482.3*

422*

211*

170.8*

9.80.46*

7.50.13*

Wire Type and Diameter Wire Feed Speed Dimensions Net Weight Without Gun

Solid Steel Stainless Steel Flux Cored 50700 IPM

H: 30 in (762 mm)

205 lb

.023 .045 in(0.6 1.2 mm)

.023 .045 in(0.6 1.2 mm)

.030 .045 in(0.8 1.2 mm)

(1.317.8 m/min) W: 19 in (483 mm)D: 40 in (1016 mm)

(93 kg)

* While idling

Operating Temperature Range 20C to +40C Storage Temperature Range -30C to + 50C

8/7/2019 o230693b_mil

14/52


OM-230 693 Page 10

4-2. Welding Power Source Duty Cycle And Overheating

4 Minutes Welding 6 Minutes Resting6 Minutes Welding 4 Minutes Resting

Duty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating.

If unit overheats, Thermistor (T)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orvoltage, or duty cycle beforewelding.

Y Exceeding duty cycle candamage unit and voidwarranty.

Overheating

0

15

A or V

ORReduce Duty Cycle

Minutes

duty1 4/95 150 215-A

40% Duty Cycle At 250 Amperes60% Duty Cycle At 200 Amperes

10 20 30 40 50 60 70 80 90 10050

100

150

200

250

300350400450500

% DUTY CYCLE

WELDAM

PERES

4-3. Volt-Ampere Curves

ssb1.1 10/91 196 844 / S-0700

1 Normal Volt-Ampere Curves

The volt-ampere curves show thenormal minimum and maximumvoltage and amperage outputcapabilities of the welding powersource. Curves of other settings fallbetween the curves shown.

1

0

5

10

15

20

25

30

35

0 100 200 300 400

AMPERES

VOLTS

8/7/2019 o230693b_mil

15/52


OM-230 693 Page 11

4-4. Connecting To Weld Output Terminals

803 778-A

Y Turn off power before connecting toweld output terminals.

Y Failure to properly connect weldcables may cause excessive heatand start a fire, or damage your ma-chine.

1 Weld Output Terminal

2 Supplied Weld Output Terminal Nut

3 Weld Cable Terminal4 Copper Bar

Remove supplied nut from weld output ter-

minal. Slide weld cable terminal onto weldoutput terminal and secure with nut so thatweld cable terminal is tight against copper

bar. Do not place anything between weldcable terminal and copper bar. Makesure that the surfaces of the weld cableterminal and copper bar are clean.

Tools Needed:

3/4 in (19 mm)

4

2

3

Do not placeanything between

Correct Installation Incorrect Installation

1

weld cable terminal

and copper bar.

4-5. Installing Work Cable And Clamp

Tools Needed:

3/4 in

1 Work Cable

2 Boot

Route cable through front panelopening. Slide boot onto workcable.

3 Negative () Output Terminal

Connect cable to terminal andcover connection with boot.

Close door.

2

3

1

804 909-A

8/7/2019 o230693b_mil

16/52


OM-230 693 Page 12

4-6. Connecting Spoolmatic) 15A Or 30A Gun

804 910-A

1 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

2 Weld Cable

3 Shielding Gas Hose

Route weld cable through openingin front panel.

Route gas hose along side panel.

4 Positive Weld Output TerminalConnect weld cable to weld outputterminal.

5 Regulator/Flowmeter

Route shielding gas hose up toregulator/flowmeter. Connect gashose to fitting on regulator/flowme-ter.

. Two welding guns may beconnected to the weldingpower source at the same time,but only one welding gun maybe in use at any one time. If thetriggers of both welding gunsare pulled at the same time, the

weld output and wirefeed motorare disabled.

Tools Needed:

3/4, 5/8 in

5

3

4

1

3

2

8/7/2019 o230693b_mil

17/52


OM-230 693 Page 13

4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python

Ref. 804 910-A / 804 936-A

. XR Edge guns prior to serial no.LE079101 require an adaptercord (part no. 195 498).

1 Gun End

2 Gun Liner3 Wire Outlet Guide

Trim excess liner from end of gunso no more than 3/32 in (2.4 mm) of

liner extends past wire outlet guide.4 Gun Securing Knob

Loosen securing knob. Insert gunend through opening until it bottomsagainst drive assembly (make suregun end does not touch drive rolls).Tighten knob.

Be sure to change drive rolls to theproper size and type.

5 Gun Trigger Plug

Insert plug into receptacle, andtighten threaded collar.

. If Aluma-Pro push/pull gun hasa listed SUP value, set the

power source to match theSUP value (see Section5-5).

32

3/32 in(2.4 mm)

. Be sure to trim liner to proper extension.

5

4

1

8/7/2019 o230693b_mil

18/52


OM-230 693 Page 14

4-8. Setting Gun Polarity For Wire Type

1 Polarity Changeover LabelInformation

Always read and follow manufacturesrecommended polarity.

1

3/4, 11/16 inRef. 190 821-A

Changing Polarity

D

D

Wire DriveAssembly Lead

Work Clamp Lead

+ Positive Terminal

Shown as shipped Electrode Positive (DCEP): Forsolid steel, stainless steel, aluminum, or flux core withgas wires (GMAW).

- Negative Terminal

Electrode Negative (DCEN): Reverse lead connectionsat terminals from that shown above for gasless flux core

wires (FCAW). Drive assembly becomes negative.

4-9. Installing Gas Supply

802 028-A / Ref. 804 912-A

Tools Needed:

Obtain gas cylinder and chain torunning gear, wall, or otherstationary support so cylindercannot fall and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side ofvalve, and open valve slightly. Gasflow blows dust and dirt from valve.Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

5 Regulator/Flowmeter GasHose Connection

6 Welding Power Source GasHose Connection

Connect customer supplied gashose between regulator/flowmetergas hose connection, and fitting onrear of welding power source.

7 Flow Adjust

Typical flow rate is 20 cfh (cubicfeet per hour). Check wiremanufacturers recommendedflow rate.

1-1/8, 5/8 in

1

2

3

Argon Gas OrMixed Gas

7

. DO NOT use Argon/Mixed gas regulator/flowmeterwith CO2shielding gas. See Parts List for optionalCO2gas regulator/flowmeter.

Rear Panel

6

4

5

8/7/2019 o230693b_mil

19/52


OM-230 693 Page 15

4-10. Installing Wire Spool And Adjusting Hub Tension

When a slight force is neededto turn spool, tension is set.

15/16 in

Use compression springwith 8 in (200 mm) spools.

Tools Needed:

072573-B / 802 922

Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wirespool, follow the procedure asshown in the illustration.

Remove thesecomponentsfrom spindle.

Spindle

SpindleInstall thesecomponentsonto spindle.

Order extra springPart No. 186 437

4-11. Positioning Jumper Links

Tools Needed:

3/8 in

Check input voltage available at

site.1 Jumper Links Access Door

Open door.

2 Jumper Link Label

Check label only one is on unit.

3 Input Voltage Jumper Links

Move jumper links to match inputvoltage.

Close and secure access door.

153 980-D / 144 916-E / 804 911-A

2

200VOLTS 230VOLTS

153980D

230VOLTS 460VOLTS 575VOLTS

144916E3

1

8/7/2019 o230693b_mil

20/52


OM-230 693 Page 16

4-12. Electrical Service Guide

Input Voltage 200 230 460 575

Input Amperes At Rated Output 48 42 21 17

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

Circuit Breaker 1, Time-Delay 2 60 50 25 20

Normal Operating 3 70 60 30 25

Min Input Conductor Size In AWG4 8 8 12 14

Max Recommended Input Conductor Length In Feet (Meters) 96(29)127(39)

206(63)

209(64)

Min Grounding Conductor Size In AWG4 8 10 12 14

Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.2 Time-Delay fuses are UL class RK5 .3 Normal Operating (general purpose no intentional delay) fuses are UL class K5 (up to and including 60 amp), and UL class H ( 65 amp and

above).4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.Y Warning: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These

recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.

8/7/2019 o230693b_mil

21/52


OM-230 693 Page 17

4-13. Selecting A Location And Connecting Input Power

804 912-A

L1L2

230 VAC, 1

18 in (457 mm) ofspace for airflow

Y Do not move or operateunit where it could tip.

3

Y Installation must meet all Nationaland Local Codes have only qualifiedpersons make this installation.

Y Disconnect and lockout/tagout inputpower before connecting input con-ductors from unit.

Y Always connect green or green/yel-low conductor to supply groundingterminal first, and never to a line ter-minal.

Y Special installation may be requiredwhere gasoline or volatile liquids arepresent see NEC Article 511 or CECSection 20.

1 Rating LabelSupply correct input power.

2 Plug (NEMA Type 6-50P)

3 Receptacle[NEMA Type 6-50R (CustomerSupplied)]

4 Input Power Cord.

Connect directly to line disconnect device ifhard wiring is required.5 Black And White Input Conductor (L1

And L2)

6 Green Or Green/Yellow GroundingConductor

7 Disconnect Device (switch shown inthe OFF position)

8 Disconnect Device Grounding Terminal

9 Disconnect Device Line Terminals

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

Connect input conductors L1 and L2 todisconnect device line terminals.

10 Over-Current ProtectionSelect type and size of over-currentprotection using Section 4-12 (fuseddisconnect switch shown).

Connect plug to receptacle if hard wiringmethod is not used.

Close and secure door on disconnect device.Remove lockout/tagout device, and placeswitch in the On position.

1

24

1

=GND/PE Earth Ground

7

L1L26

5

8

9

10

8/7/2019 o230693b_mil

22/52


OM-230 693 Page 18

4-14. Threading Welding Wire

1 Wire Spool

2 Welding Wire3 Inlet Wire Guide

4 Pressure Adjustment Knob

5 Drive Roll6 Outlet Wire Guide7 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

6 in(150 mm)

. Hold wire tightly to keep itfrom unraveling.

WOOD

Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;continue to hold wire.

Close and tighten pressureassembly, and let go of wire.

Remove gun nozzle and contact tip. Turn On.

Press gun trigger until wirecomes out of gun. Reinstall

contact tip and nozzle

Feed wire to check drive roll pressure.Tighten knob enough to prevent slipping.

Cut off wire. Closeand latch door.

Ref. 804 913-A

Tighten

1234

. Use pressure indicator

scale to set a desireddrive roll pressure.

PressureIndicator

Scale

Tighten

1234

4

7

5 6

213

8/7/2019 o230693b_mil

23/52


OM-230 693 Page 19

Notes

8/7/2019 o230693b_mil

24/52


OM-230 693 Page 20

4-15. Weld Parameters

8/7/2019 o230693b_mil

25/52


OM-230 693 Page 21

226 650-B

8/7/2019 o230693b_mil

26/52


OM-230 693 Page 22

SECTION 5 OPERATION

5-1. Controls

226 647-B

1 Voltage Control

Turn control clockwise to increasevoltage.

2 Wire Speed Control

Turn control clockwise to increase wire

feed speed.3 Voltmeter4 Wire Feed Speed Meter

2

3

. This unit has three automatic timers included in its operation to help save contacttips, gas, and wire:

Tip Saver Weld output shuts off if tip is shorted to work surface.

Safety shut-off Weld output will shut off if no arc is detected within 3 seconds aftergun trigger is depressed.

Jog mode When loading a new roll of wire or if the gun trigger is accidentallypressed, gas will shut off after 1 minute and wire will shut off after 2 minutes savingwire and gas.

1

4

8/7/2019 o230693b_mil

27/52


OM-230 693 Page 23

JOG Mode

If the trigger on either gun is held for morethan 3 seconds without striking an arc, theunit will automatically shut off weld power(and shielding gas output on MIG gun

only), but will feed wire continuously at thepreset wire feed speed (which may befaster or slower than Runin Speed) untiltrigger is released.

Runin Wire Feed Speed Settings

Runin settings for the MIG and SpoolGuns are independently set and stored inunit memory. The settings are in percent ofthe welding wire feed speed preset. Bothsettings are adjustable from 25 to 150percent.

MIG Gun Runin is factory set at 100%

which is recommended for most wire sizesand types.

Spool Gun Runin is factory set at 50%which is recommended for .030 & .035wire. A Runin setting of 25% isrecommended for .047 wire.

To check Runin settings, start with thepower switch OFF. Press and hold the MIGor Spool Gun Trigger while turning thepower switch ON. The unit will power upwith both the displays reading 888, thenthe voltage display will read runand thewire feed display will read the presetRunin percentage from memory for thegun selected. To return to the weld modewithout making a change, simply release

trigger and pull the trigger againmomentarily (one second).

To change Runin settings, start with thepower switch OFF. Press and hold the MIGor Spool Gun Trigger while turning the

power switch ON. The unit will power upwith both the displays reading 888, thenthe voltage display will read runand thewire feed display will read the preset Runin percentage from memory for the gun se-lected. To change the Runin value, re-lease the trigger and turn the wire feed con-trol knob (or the wire feed adjustment knoblocated on the bottom handle of the spoolgun) to the desired setting for the selectedgun. To return to weld mode after the Runin speed change, pull the trigger momen-tarily (one second).

8/7/2019 o230693b_mil

28/52


OM-230 693 Page 24

5-2. Voltmeter And Wire Feed Speed Meter Operation

1 Voltmeter

2 Wire Feed Speed Meter

Power Up Status

Both meters display 888at unit power up.After 0.5 seconds, preset values appear onboth meters. The settings for the last activegun used will be the default at initial powerup of the unit. If the power is reset to quickly,characters other than888may appear. Toreset, turn power off for at least 3 seconds,then turn power back on.

Welding Status

When either a MIG gun or spool gun triggeris pressed and a welding arc is established,the voltmeter displays actual weld voltage.When the gun trigger is released andwelding arc extinguished, the voltmeterdisplays the last actual voltage for 5seconds and then returns to preset voltage.If welding resumes before unit displayspreset voltage, actual welding voltage willappear on the voltmeter.

The wire feed speed meter always displayspreset wire feed speed (IPM).

Gun Selection

The wire feed speed meter will display

preset wire feed speed (IPM) for theappropriate gun selection either MIG,Spool or Push/Pull gun. To preset desiredwire feed speed, connect desired gun,press gun trigger for one second, andrelease trigger. The meter preset will beretained by the meter board until a differentgun is connected and preset is performedor the unit is turned off and back on. Thesettings for the last active gun used will bethe default at initial power up of the unit.

1 2

5-3. Jog Mode

If the trigger on either gun is held for more than 3 seconds without striking an arc, the unit will automatically shut offweld power (and shielding gas output on MIG or push/pull gun), but will feed wire continuously at the preset wire feedspeed (which may be faster or slower than Runin Speed) until trigger is released. Jog wire feed speed is the same asweld wire feed speed, so any time jog speed is changed, be sure to change back to weld wire feed speed before weld-ing. Jog wire feed speed for the spool gun and push/pull gun is limited to 300 ipm (7.6 m/min).

8/7/2019 o230693b_mil

29/52

8/7/2019 o230693b_mil

30/52


OM-230 693 Page 26

. Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high.

5-5. Set Up Push Motor Torque (SUP) Or Reset (rES)

1 Voltage Control2 Wire Speed Control3 Voltmeter4 Wire Feed Speed MeterDepress the gun trigger while turning onthe power switch until the left meterdisplays (run).

Rotate the left knob counterclockwise(CCW) to find the particular item, and rotatethe right knob to change the setting.

The following items can be adjusted byrotating the left knob counterclockwise(CCW):Set up Push Motor Torque (SUP) Thisfeature is only active when a push/pull gunis connected to the welding power source.The (SUP) setting will adjust theover-torque limit of the push motor insidethe welding power source. The range is0-250 and the default value is 130.Increasing this setting will increase the

over-torque limit and speed up the remotewire feed speed motor.

. If Aluma-Pro push/pull gun has a listedSUP value, set the power source tomatch the SUP value.

To save settings and exit the (SUP) menu,depress the gun trigger.Reset (rES) Rotate the right knob toselect ON. Press and release gun trigger toreset system to factory default values.

2

3

1

4

8/7/2019 o230693b_mil

31/52

8/7/2019 o230693b_mil

32/52


OM-230 693 Page 28

6-4. Aligning Drive Rolls and Wire Guide

Y Turn Off power.

View is from top of drive rollslooking down with pressureassembly open.

1 Drive Roll Securing Nut

2 Drive Roll3 Wire Guide4 Welding Wire

5 Drive GearInsert screwdriver, and turn screwin or out until drive roll groove linesup with wire guide.

Close pressure roll assembly.

Ref. 800 412-A

Correct Incorrect43

21

5

Tools Needed:

8/7/2019 o230693b_mil

33/52

8/7/2019 o230693b_mil

34/52


OM-230 693 Page 30

Trouble Remedy

No wire feed. Turn Wire Speed control to higher setting (see Section 5-1).

Clear obstruction in gun contact tip or liner (see welding gun Owners Manual).

Readjust drive roll pressure (see Section 4-14).

Change to correct size drive rolls (see Section 6-3).

Rethread welding wire (see Section 4-14).

HL.P 002 appears on meters. Thermistor T is detecting an overheating condition. Wait for unit to coolallowing the fan to run. After unit is cool, If HL.P 002 message remains, contact Factory AuthorizedService Agent (see Section 6-2).

HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causingshort circuit (see Section 5-2) . If message remains, have Factory Authorized Service Agent check forshorted trigger leads.

HL.P 005 appears on meters. Wire feed malfunction. Check wire feed delivery system.

Check gun trigger and leads. Repair or replace gun if necessary.

Have Factory Authorized Service Agent check main control board.

8/7/2019 o230693b_mil

35/52

OM-230 693 Page 31

Notes

8/7/2019 o230693b_mil

36/52

OM-230 693 Page 32

SECTION 7 ELECTRICAL DIAGRAM

Figure 7-1. Circuit Diagram

8/7/2019 o230693b_mil

37/52

OM-230 693 Page 33

229 485-A

8/7/2019 o230693b_mil

38/52

OM-230 693 Page 34

SECTION 8 MIG WELDING (GMAW) GUIDELINES

8-1. Typical MIG Process Connections

Y Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible.

Wire Feeder/Power Source

Workpiece

Gun

Regulator/Flowmeter

Gas

Shielding Gas

Work Clamp

mig1 200705 / 801 909-A

8/7/2019 o230693b_mil

39/52

OM-230 693 Page 35

8-2. Typical MIG Process Control Settings

. These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be surethey comply to specifications.

1/8 or.125 in

Material thickness determines weldparameters.

Convert Material

(.001 in = 1 ampere).125 in = 125 A

Select Wire Size

Wire Size Amperage Range

.030 in

.035 in

.023 in

40 145 A

50 180 A

30 90 A

.035 in

Select Wire Speed

Select Voltage

Wire Recommendation

.030 in

.035 in

.023 in2 in per ampere

1.6 in per ampere

3.5 in per ampere

Wire Speed

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

3.5 x 125 A = 437 ipm

Set voltage midway between high/low voltage.

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

125 A based on 1/8 in

Thickness to

(Amperage)

material thickness

Size (Approx.)

Amperage (A)

ipm = inch per minute

Voltage controls height andwidth of weld bead.

Wire speed (amperage) controls weldpenetration (wire speed = burn-off rate)

8/7/2019 o230693b_mil

40/52

OM-230 693 Page 36

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.

1 Hold Gun and Control GunTrigger

2 Workpiece

3 Work Clamp

4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)5 Cradle Gun and Rest Hand onWorkpiece

23

5

4

90 90

0-15

45

45

GROOVE WELDS

FILLET WELDS

End View Of Work Angle Side View Of Gun Angle

End View Of Work Angle Side View Of Gun Angle

1

0-15

S-0421-A

8/7/2019 o230693b_mil

41/52

OM-230 693 Page 37

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.

Short Normal Long

Short Normal Long

10

10

GUN ANGLES AND WELD BEAD PROFILES

ELECTRODE EXTENSIONS (STICKOUT)

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Push

Perpendicular Drag

GUN TRAVEL SPEED

Slow Normal Fast

S-0634

8/7/2019 o230693b_mil

42/52

OM-230 693 Page 38

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.

1 Stringer Bead SteadyMovement Along Seam

2 Weave Bead Side To SideMovement Along Seam

3 Weave Patterns

Use weave patterns to cover a widearea in one pass of the electrode.

S-0054-A

3

1 2

8-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits2 Rough, Uneven Bead

3 Slight Crater During Welding4 Bad Overlap

5 Poor Penetration

5

42 3

1

S-0053-A

8-7. Good Weld Bead Characteristics

1 Fine Spatter

2 Uniform Bead

3 Moderate Crater DuringWelding

Weld a new bead or layer for each1/8 in (3.2 mm) thickness in metalsbeing welded.

4 No Overlap

5 Good Penetration into BaseMetal

S-0052-B

2 3

1

4

5

8/7/2019 o230693b_mil

43/52

OM-230 693 Page 39

8-8. Troubleshooting Excessive Spatter

Excessive Spatter scattering of molten metal particles thatcool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

8-9. Troubleshooting Porosity

Porosity small cavities or holes resulting from gas pocketsin weld metal.

S-0635


Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

8-10. Troubleshooting Excessive Penetration

Good Penetration

Excessive Penetration weld metal melting through base metaland hanging underneath weld.

Excessive PenetrationS-0639


Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase travel speed.

8/7/2019 o230693b_mil

44/52

OM-230 693 Page 40

8-11. Troubleshooting Lack Of Penetration

Lack Of Penetration shallowfusion between weld metal andbase metal.

Lack of Penetration Good PenetrationS-0638


Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

maintaining proper welding wire extension and arc characteristics.Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

8-12. Troubleshooting Incomplete Fusion

Incomplete Fusion failure of weld metal to fuse completely withbase metal or a preceeding weld bead.

S-0637


Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface beforewelding.

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

8-13. Troubleshooting Burn-Through

Burn-Through weld metal melting completely through base metalresulting in holes where no metal remains.

S-0640


Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

8/7/2019 o230693b_mil

45/52

OM-230 693 Page 41

8-14. Troubleshooting Waviness Of Bead

Waviness Of Bead weld metal that is not parallel and does not coverjoint formed by base metal.

S-0641


Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

8-15. Troubleshooting Distortion

Distortion contraction of weld metal during welding that forcesbase metal to move.

Base metal movesin the direction of

the weld bead.S-0642


Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

8/7/2019 o230693b_mil

46/52

OM-230 693 Page 42

8-16. Common MIG Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixtures) ofshielding gases have been developed over the years. The most commonly used shielding gases are listed in thefollowing table.

Application

GasSpray Arc Steel Short Circuiting Steel

Short CircuitingStainless Steel

Aluminum

Argon XArgon + 25% CO2 X

80% or greater Argon +balance CO2 or Oxygen

X X1

100% CO2 X

Tri-Mix2 X1 Limited short circuiting use

2 90% HE + 7-1/2% AR + 2-1/2% CO2

8-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy

Wire feed motor operates, but

Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.w re oes no ee .

Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to matchwire size and type if necessary.

Wire spool brake pressure too high. Decrease brake pressure on wire spool.

Restriction in the gun and/or assembly. Check and replace cable, gun, and contact t ip i fdamaged. Check size of contact tip and cable liner,replace if necessary.

Wire curling up in front of the

Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.w re ee ro s ( r nes ng).

Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length

and diameter, replace if necessary.

Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gunend into housing just enough so it does not touch wirefeed rolls.

Dirty or damaged (kinked) liner. Replace liner.

Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.

Gas nozzle plugged. Clean or replace gas nozzle.

Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.

Restriction in gas line. Check gas hose between flowmeter and wire feeder, andgas hose in gun and cable assembly.

Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.

Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gassolenoid valve.

Incorrect primary voltage connected to welding powersource.

Check primary voltage and relink welding power sourcefor correct voltage.

8/7/2019 o230693b_mil

47/52

OM-230 693 Page 43

Problem RemedyProbable Cause

Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worndrive rolls if necessary.

Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.

Incorrect voltage setting for selected wire feed speed onwelding power source.

Readjust welding parameters.

Loose connections at the gun weld cable or work cable. Check and tighten all connections.

Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.

8/7/2019 o230693b_mil

48/52

OM-230 693 Page 44

SECTION 9 PARTS LIST

9-1. Drive Roll And Wire Guide Kits

Note Base selection of drive rolls upon the following recommended usages:1 V-Grooved rolls for hard wire.

2 U-Grooved rolls for soft and soft shelled cored wires.3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).4 V-Knurled rolls for hard shelled cored wires.

5 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combinationwith U-Grooved).

Ref. S-0026-B/7-91

Wire Diameter

Fraction Decimal Metric

.023/.025 in.

.030 in.

.035 in.

.045 in.

.023/.025 in.

.030 in.

.035 in.

.045 in.

0.6 mm

0.8 mm

0.9 mm

1.2 mm

Kit No.

087 131

079 594

079 595

079 596

Drive Roll

Part No. Type

087 130

053 695

053 700

053 697

V-Grooved

V-Grooved

V-Grooved

V-Grooved

Inlet

056 192

056 192

056 192

056 193

Wire Guide

.030/.035 in. .030/.035 in. 0.8/0.9 mm 204 579 203 526 V-Grooved 056 192

8/7/2019 o230693b_mil

49/52

Notes

8/7/2019 o230693b_mil

50/52

Notes

8/7/2019 o230693b_mil

51/52

Warranty Questions?

Call1-800-4-A-MILLERfor your localMiller distributor.

miller_warr 20070

Your distributor also givesyou ...

ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.

SupportNeed fast answers to thetough welding questions?Contact your distributor.The expertise of thedistributor and Miller isthere to help you, everystep of the way.

Effective January 1, 2007(Equipment with a serial number preface of LH or newer)This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY Subject to the terms and conditionsbelow, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants toits original retail purchaser that new Miller equipment sold afterthe effective date of this limited warranty is free of defects inmaterial and workmanship at the time it is shipped

o230693b_mil

Documents

Transcript of o230693b_mil