Page 2 - To locate your nearest; Thank you; From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearest distributor or service agency call...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-1324 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _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 hazards with this procedure! The possible hazards are shown in the adjoin...
Page 6 - WELDING can cause fire or explosion.
OM-1324 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RAYS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protec...
Page 9 - Symboles utilisés; Dangers relatifs au soudage à l’arc; UNE DÉCHARGE ÉLECTRIQUE peut
OM-1324 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Y 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 d...
Page 11 - Proposition californienne 65 Avertissements
OM-1324 Page 7 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. ...
Page 12 - Principales normes de sécurité; Information EMF
OM-1324 Page 8 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Co...
Page 14 - A or V
OM-1324 Page 10 3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before weldin...
Page 24 - -2. Weld Parameter Chart For 115 VAC Model; Selecting
OM-1324 Page 20 5-2. Weld Parameter Chart For 115 VAC Model Selecting Wire, Gas and Control Settings What Material Are you Welding Tri − Mix 90% He / 7.5% Ar / 2.5% CO 2 No Shielding Gas required. Good for windy or outdoor applications. C 25 Gas Mixture 75% Ar / 25% CO 2 (Ar / CO 2 produces less spa...
Page 26 - -3. Weld Parameter Chart For 230 VAC Model
OM-1324 Page 22 5-3. Weld Parameter Chart For 230 VAC Model Quick Change Dual Grooved Drive Rolls: Match feedroll groove to diameter of wire being used. Set Tension knob setting to 3 at start. Adjust tension per instructions in the manual. Wire Diameters.024” (0.6 mm).030” (0.8 mm).035” (0.9 mm).045...
Page 28 - Months; -3. Drive Motor Protection And Tip Saver/Short Circuit Protection; A. Drive Motor Protection
OM-1324 Page 24 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean mon...
Page 29 - -4. Changing Drive Roll Or Wire Inlet Guide
OM-1324 Page 25 6-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place.2 Drive Roll The drive roll consists of two differ- ent s...
Page 33 - Figure 7-1. Circuit Diagram For 115 VAC Model
OM-1324 Page 29 SECTION 7 − ELECTRICAL DIAGRAM 203 765 Figure 7-1. Circuit Diagram For 115 VAC Model
Page 34 - Figure 7-2. Circuit Diagram For 230 VAC Model
OM-1324 Page 30 203 794 Figure 7-2. Circuit Diagram For 230 VAC Model
Page 36 - -2. Typical MIG Process Control Settings; NOTE
OM-1324 Page 32 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 sure they comply to specifications. NOTE 1/8 or .125 in Material thickness determines weld parame...
Page 37 - and tip of wire is positioned correctly on seam.
OM-1324 Page 33 8-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. NOTE 1 Hold Gun and Control Gu...
Page 38 - -4. Conditions That Affect Weld Bead Shape
OM-1324 Page 34 8-4. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. NOTE Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND...
Page 39 - multiple stringer beads works better.
OM-1324 Page 35 8-5. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. NOTE 1 Stringer Bead − Steady Movement Along Seam ...
Page 40 - Excessive Spatter; Porosity
OM-1324 Page 36 8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool 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. El...
Page 50 - Notes
Page 51 - (Equipment with a serial number preface of “LG” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding ...
Page 52 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters − USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 E...