Page 2 - 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 nearestdistributor 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 - SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-230 693 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 hazardswith this procedure! The possible hazards are shown inthe adjoi...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; California Proposition 65 Warnings
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 siz...
Page 9 - SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION; Symboles utilisés; Dangers relatifs au soudage à l’arc
OM-230 693 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_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 comp...
Page 10 - peuvent
OM-230 693 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provo-quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS D’ARC peuvent entraî-ner de...
Page 11 - LIRE LES INSTRUCTIONS.; Proposition californienne 65 Avertissements
OM-230 693 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 ouà proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité deproduits inflammables. ...
Page 13 - SECTION 3 − DEFINITIONS; Symbols And Definitions; SECTION 4 − INSTALLATION; Specifications
. 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 Switch While Welding V Volts Increase On Off Gas Metal Arc Welding (GMAW) Gun Wire Feed Spool Gun Gas Input Gas Output Voltage Input...
Page 14 - Welding Power Source Duty Cycle And Overheating; A or V
. A complete Parts List is available at www.MillerWelds.com OM-230 693 Page 10 4-2. Welding Power Source Duty Cycle And Overheating 4 Minutes Welding 6 Minutes Resting 6 Minutes Welding 4 Minutes Resting Duty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating. If un...
Page 15 - Connecting To Weld Output Terminals
. A complete Parts List is available at www.MillerWelds.com 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 ...
Page 16 - Connecting Spoolmatic
. A complete Parts List is available at www.MillerWelds.com 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...
Page 18 - Setting Gun Polarity For Wire Type; Changing Polarity; Installing Gas Supply
. A complete Parts List is available at www.MillerWelds.com OM-230 693 Page 14 4-8. Setting Gun Polarity For Wire Type 1 Polarity Changeover LabelInformation Always read and follow manufacture’srecommended polarity. 1 3/4, 11/16 in Ref. 190 821-A Changing Polarity D D Wire DriveAssembly Lead Work Cl...
Page 19 - -10. Installing Wire Spool And Adjusting Hub Tension
. A complete Parts List is available at www.MillerWelds.com 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 ...
Page 21 - -13. Selecting A Location And Connecting Input Power
. A complete Parts List is available at www.MillerWelds.com OM-230 693 Page 17 4-13. Selecting A Location And Connecting Input Power 804 912-A L1 L2 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 −...
Page 23 - Notes
. A complete Parts List is available at www.MillerWelds.com OM-230 693 Page 19 Notes
Page 26 - SECTION 5 − OPERATION; Controls
. A complete Parts List is available at www.MillerWelds.com 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 wirefeed speed. 3 Voltmeter 4 Wire Feed Speed Meter 2 3 . ...
Page 28 - Voltmeter And Wire Feed Speed Meter Operation; Jog Mode
. A complete Parts List is available at www.MillerWelds.com 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 888 at unit power up. After 0.5 seconds, preset values appear onboth meters. The settings for the ...
Page 29 - Timers
. A complete Parts List is available at www.MillerWelds.com OM-230 693 Page 25 5-4. Timers 1 Voltage Control 2 Wire Speed Control 3 Voltmeter 4 Wire Feed Speed Meter To enter the TIMERS menu press and holdthe gun trigger while turning on the powerswitch until the left meter displays (run),then relea...
Page 31 - SECTION 6 − MAINTENANCE &TROUBLESHOOTING; Routine Maintenance
. A complete Parts List is available at www.MillerWelds.com OM-230 693 Page 27 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more oftenduring severe conditions. n = Check Z = Change ~ = Clean l = Replace * To be done by Factor...
Page 32 - Aligning Drive Rolls and Wire Guide
. A complete Parts List is available at www.MillerWelds.com 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 Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert scr...
Page 33 - Troubleshooting
. A complete Parts List is available at www.MillerWelds.com OM-230 693 Page 29 6-5. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 4-13). Replace building line fuse or reset circuit breaker if open (see Section 4-13). Secure gun t...
Page 36 - SECTION 7 − ELECTRICAL DIAGRAM
OM-230 693 Page 32 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram
Page 38 - Typical MIG Process Connections
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 ...
Page 39 - Typical MIG Process Control Settings
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 weldparamete...
Page 40 - Holding And Positioning Welding Gun
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 Gun...
Page 41 - Conditions That Affect Weld Bead Shape
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 ...
Page 45 - -14. Troubleshooting − Waviness Of Bead
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 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm)...
Page 46 - -17. Troubleshooting Guide For Semiautomatic Welding Equipment
OM-230 693 Page 42 8-16. Common MIG Shielding Gases This 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 Gas ...
Page 51 - (Equipment with a serial number preface of “LH” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 2007−01 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?Con...
Page 52 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters−USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European H...
