Miller Millermatic Spoolmate 185 Spool Gun Owner's Manual
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Miller Millermatic Spoolmate 185 Spool Gun Owner's Manual

Miller Millermatic Spoolmate 185 Spool Gun Owner's Manual

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Millermatic Pulser
M-15 Gun And Spoolmate
185 Spool Gun
OM-1322
May 2001
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R
200 070C

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Summary of Contents for Miller Millermatic Spoolmate 185 Spool Gun

  • Page 1 OM-1322 200 070C May 2001 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic Pulser M-15 Gun And Spoolmate 185 Spool Gun Visit our website at www.MillerWelds.com...
  • Page 2 They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.
  • Page 3 TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 6 – MIG WELDING (GMAW) GUIDELINES ........6-1.
  • Page 5 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
  • Page 7 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.
  • Page 8 1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.
  • Page 9 SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.
  • Page 11 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...
  • Page 12 1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
  • Page 13 SECTION 2 – INSTALLATION 2-1. Welding Power Source And MIG Gun Specifications Max. Open Amps Input at Rated Output, 50 or 60 Hz, Single-Phase Rated Output Amperage Circuit 200 (208) V 230 V 240 V Voltage DC Range DC 160 A at 26 VDC, 30-200 6.36 5.45...
  • Page 14 2-3. Welding Power Source 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.
  • Page 15 2-5. Spool Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. • Do not weld at rated load longer than shown below. • Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Definition .023 To .035 in (0.6 To 0.9 mm) Aluminum Wire...
  • Page 16 2-7. Installing Cylinder Rack Wheels Welding Power Source Block front casters to prevent Crimp movement. Block up rear of unit. Dual Cylinder Support Bracket Chain Install supplied chains onto dual bracket. Dual Cylinder Rack Axle Wheel Washer Retaining Ring Install axle, wheel, washer, and retaining ring to both sides as shown.
  • Page 17 2-8. Installing Work Clamp Work Cable Boot Route cable through front panel opening. Slide boot onto work cable. Negative (–) Output Terminal Connect cable to terminal and cover connection with boot. Close door. PULSE Tools Needed: – 203006 1/2, 3/4 in 802 713 2-9.
  • Page 18 2-10. Connecting A Spool Gun Barbed Fitting If spool gun gas hose is equipped with a pre-installed barbed fitting, cut off fitting from end of hose. Connect spool gun gas hose to barbed fitting. Pulse Weld Terminal Connect spool gun cable to pulse weld terminal.
  • Page 19 2-12. Installing Gas Supply Obtain gas cylinders and chain to running gear, wall, or other stationary support so cylinders cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.
  • Page 20 2-13. Installing MIG Wire Spool and Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in ST-072573-B OM-1322 Page 16...
  • Page 21 2-14. Installing Spool Gun Wire Spool And Threading Welding Wire Thumb Screw Spool Cover Remove thumb screw and spool Tools Needed: cover. Hub Tension Nut Wire Spool Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.
  • Page 22 2-15. Positioning Jumper Links Check input voltage available at Before setting jumper link, check input voltage and link site and listed on the machine rating unit for voltage closest to the input voltage at the site. label. Jumper Links Access Door Open door.
  • Page 23 2-17. Selecting A Location And Connecting Input Power Rating Label Supply correct input power. Plug (NEMA Type 6-50P) Receptacle (NEMA Type 6-50R) Connect plug to receptacle. Input And Grounding 18 in (457 mm) of Y Do not move or operate unit Conductors space for airflow where it could tip.
  • Page 24 2-18. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open pressure assembly.
  • Page 25 2-19. Installing Optional Curved Or 9 in Straight Barrel On Spoolmate 185 Spool Gun Y Turn Off and disconnect input power. Contact Adapter Remove existing barrel from contact adapter. Gas Hose Disconnect gas hose from gas nipple. Straight Barrel Curved Barrel Locking Nut Before tightening locking nut on the curved barrel, the barrel...
  • Page 26 2-20. Using Gun/Cable Holder Side Panel Latch Cable Holder Press latch down to release and open door. Holster (2) Wrap cable around cable holder, and place gun nozzle into holster. 802 726 OM-1322 Page 22...
  • Page 27 SECTION 3 – OPERATION 3-1. Controls WIRE SPEED VOLTAGE RATED OUTPUT AMPERA GE VOL TAGE DUTY CYCLE MAX OCV NEMA CLASS I (60) DO NO T SWITCH WHILE WELDING –1 –2 –3 –4 –5 ARC LENGTH ( PULSE ONL PULSE ONLY ) MIG GUN SPOOL GUN 200 034-B...
  • Page 28 3-2. Weld Parameter Chart This chart provides starting parameters assuming that line voltage at the machine location is close to the machine linked voltage setting (within several volts higher or lower). If line voltage is significantly higher or lower than the linked voltage setting, welding parameters will need to be adjusted accordingly (e.g.
  • Page 29 200 796-A OM-1322 Page 25...
  • Page 30 3-3. Parameter Adjustment Guide Problem Probable Cause Remedy Erratic arc, ball at end of wire Arc Length control set too low. Increase arc length setting slightly (see Section 3-1). too large at time of transfer to weld puddle. Wire shorting (stubbing) into Wire speed set too high. Decrease wire speed setting slightly (see Section 3-1).
  • Page 31 SECTION 4 – MAINTENANCE &TROUBLESHOOTING 4-1. Routine Maintenance Maintain more often Y Disconnect power during severe conditions. before maintaining. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Remove drive roll and Blow out or vacuum inside.
  • Page 32 4-4. Replacing Gun Contact Tip Y Turn Off power. Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: Ref. 800 797-C 4-5. Changing Drive Roll and Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw.
  • Page 33 4-6. Aligning Drive Rolls and Wire Guide Y Turn Off power. View is from top of drive rolls look- ing down with pressure assembly open. Drive Roll Securing Nut Correct Incorrect Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide.
  • Page 34 4-7. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit first. 5/16 in, 10 mm Head Tube Remove nozzle, contact tip, and adapter. 5/16 in 10 mm Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Blow out gun casing.
  • Page 35 4-8. Replacing Switch And/Or Head Tube Y Disconnect gun first. Remove handle locking nut. Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure.
  • Page 36 4-9. Changing Drive And Push Rolls On Spoolmate 185 Y Turn Off power at welding power source first. Drive Roll Cover Remove cover. Changing Push Roll: To remove push roll: Push Roll Screw Washer Push Roll Remove screw and washer, and lift out push roll.
  • Page 37 4-10. Changing Liner On Spoolmate 185 Y Turn Off power at welding power source first. Nozzle Contact Tip Liner Remove and replace liner. Reinstall parts as shown. Tools Needed: Ref. 801 891-A 4-11. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-17).
  • Page 38 Trouble Remedy Low, high, or erratic wire speed. Readjust front panel settings (see Section 3-1). Change to correct size drive rolls (see Section 4-5). Readjust drive roll pressure (see Section 2-18). Replace inlet guide, contact tip, and/or liner if necessary (see Sections 4-4 and 4-7). Check position of input jumper links (see Section 2-15).
  • Page 39 SECTION 5 – ELECTRICAL DIAGRAM 203 535-A Figure 5-1. Welding Power Source Circuit Diagram OM-1322 Page 35...
  • Page 40 GREEN WHITE BLACK 186 451 Figure 5-2. Spool Gun Circuit Diagram OM-1322 Page 36...

  • Page 41: Section 6 - Mig Welding (Gmaw) Guidelines

    SECTION 6 – MIG WELDING (GMAW) GUIDELINES 6-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery Regulator/ cables before welding on a Flowmeter vehicle. Place work clamp as close to the weld as possible. Shielding Supply Wire Feeder/...

  • Page 42: Typical Mig Process Control Settings

    6-2. Typical MIG Process Control Settings NOTE 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. Material thickness determines weld parameters. 1/8 or Convert Material .125 in Thickness to...

  • Page 43: Holding And Positioning Welding Gun

    6-3. Holding And Positioning Welding Gun NOTE 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. Hold Gun and Control Gun Trigger Workpiece...

  • Page 44: Conditions That Affect Weld Bead Shape

    6-4. Conditions That Affect Weld Bead Shape NOTE 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. ° Push ° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...

  • Page 45: Gun Movement During Welding

    6-5. Gun Movement During Welding NOTE 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. Stringer Bead – Steady Movement Along Seam Weave Bead –...

  • Page 46: Troubleshooting - Excessive Spatter

    6-8. 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. Electrode extension (stickout) too long.

  • Page 47: Troubleshooting - Excessive Penetration

    6-11. Troubleshooting – Lack Of Penetration Lack Of Penetration – shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions 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.

  • Page 48: Troubleshooting - Waviness Of Bead

    6-14. Troubleshooting – Waviness Of Bead Waviness Of Bead – weld metal that is not parallel and does not cover joint 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) beyond nozzle. Unsteady hand.

  • Page 49: Common Mig Shielding Gases

    6-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
  • Page 50 Problem Probable Cause Remedy Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive 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 on Readjust welding parameters.

  • Page 51: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. 802 718 Figure 7-1. Main Assembly OM-1322 Page 47...
  • Page 52 Item Dia. Part Mkgs. Description Quantity Figure 7-1. Main Assembly ... Figure 7-2 BAFFLE,CENTER ...........
  • Page 53 Hardware is common and not available unless listed. 802 719 Figure 7-2. Baffle, Center w/Components OM-1322 Page 49...
  • Page 54 Item Dia. Part Mkgs. Description Quantity Figure 7-2. Baffle, Center w/Components (Figure 7-1 Item 1) ....196001 SPOOL HUB ASSEMBLY,(CONSISTING OF) ......
  • Page 55 Hardware is common and not available unless listed. 802 728 Figure 7-3. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 7-3. Panel, Rear w/Components (Figure 7-1 Item 2) ... . . 049399 NUT, 312–18 PUSH ON .63D .07H STL .
  • Page 56 Hardware is common and not available unless listed. 802 720 Figure 7-4. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 7-4. Panel, Front w/Components (Figure 7-1 Item 17) ... . . 199898 PANEL,FRONT CONTROL .
  • Page 57 Item Part Description Quantity 169589 Figure 7-5. M-15 Gun (Figure 7-1 Item 36) ... . . 169715 NOZZLE,SLIP TYPE .500 ORF FLUSH ....... ♦087299 .
  • Page 58 Item Dia. Part Mkgs. Description Quantity Figure 7-6. Wire Drive And Gears (Figure 7-2 Item 25) 197633 ... . . 602009 SCREW,.250-20 x 1.25 soc hd gr 8 ........
  • Page 59 Table 7-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire. U-Grooved rolls for soft and soft shelled cored wires. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). V-Knurled rolls for hard shelled cored wires.
  • Page 60 Hardware is common and not available unless listed. 801 900-C Figure 7-7. Spool Gun Assembly OM-1322 Page 56...
  • Page 61 Item Dia. Part Quantity Mkgs. Description 043701 Figure 7-7. Spool Gun Assembly (Figure 7-1 Item 19) ..186416 TRIGGER SWITCH ..........
  • Page 62 802 532 Figure 7-8. Optional Barrel Assembly Quantity Curved Straight Item Part Description 198 371 198 372 Figure 7-8. Optional Barrel Assembly ... . . 197570 PIN,ANTIROTATION .078 DIA X 3/16 LG .
  • Page 63 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...

  • Page 64: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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