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ISO 9001 Quality System Standard. particular model are also provided. 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.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
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D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. 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.
1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
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Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser.
Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
3-3. Connecting Spool Gun To Millermatic 140/180 Models A. Installing Optional Spool Gun Switch In Millermatic 140/180 Models Renegade Passport Plus Models: Discard switch assembly; unit pre−wired for spool gun option. Go to Section 3-5 or 3-6. Turn Off unit, and disconnect input power.
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B. Connecting Spool Gun To Millermatic 140/180 Drive Assembly Spool Gun Gun Securing Knob Gun End Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten gun securing knob. Spool gun must be inserted completely to prevent leakage of shielding gas.
3-4. Connecting Spool Gun To Millermatic 211 Auto-Sett Drive Assembly Spool Gun Gun Securing Knob Gun End Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten gun securing knob. Spool gun must be inserted completely to prevent leakage of shielding gas.
3-5. Connecting Spool Gun To Millermatic Passport Plus Drive Assembly Spool Gun Gun Securing Knob Gun End Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten gun securing knob. Spool gun must be inserted completely to prevent leakage of shielding gas.
3-6. Connecting Spool Gun To Renegade 180 Drive Assembly Spool Gun Gun Securing Knob Gun End Loosen gun securing knob. Insert end through opening until it bottoms against drive assembly. Tighten gun securing knob. Be sure that gun end is tight against drive assembly.
3-7. Installing 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.
SECTION 4 − OPERATION 4-1. Controls For Millermatic 140/180 Models A. Spool Gun Operation On Millermatic 140/180 Models Spool Gun/MIG Gun switch on Millermatic 140/180 must be in Spool Gun position for spool gun to operate. Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual.
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B. Weld Parameter Chart For Millermatic 140 Model w/Auto−SetE Auto−Sett − SIMPLE SETUP FOR WELDING MILD STEEL Example: .030” diameter wire, welding 18 ga. material. Activate Auto−Sett by selecting the diameter of the welding wire .024” Auto−Set* with the WIRE SPEED knob. WELD WIRE .030”...
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Manual Setup Refer to chart below to select Voltage and Wire Speed based on thickness of metal being welded. 1. Number on right of slash is Wire Speed Knob Setting. (Example: 4 / 65) M A TER I A L T H I 2.
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C. Weld Parameter Chart For Millermatic 140 Model w/Factory Set Non-Wire Speed Tracking Mode Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded. 1. Number on left of 2. Number on right slash is Voltage of slash is Wire Knob Setting.
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NOTE: Settings are approximate. Adjust as required. “---” Means not recommended. “*” Thicker materials can be welded using proper technique, joint preparation and multiple passes. IMPORTANT: Match drive roll groove to diameter of wire being used. Set Tension knob setting to 3 at start. Adjust tension per instructions in the manual.
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D. Weld Parameter Chart For Millermatic 180 Model w/Factory Set Non-Wire Speed Tracking Mode Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded. 1. Number on left of 2. Number on right slash is Voltage of slash is Wire Knob Setting.
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NOTE: Settings are approximate. Adjust as required. “−−−” Means not recommended. Thicker materials can be welded using proper technique, joint preparation and multiple passes. IMPORTANT: Match drive roll groove to diameter of wire being used. Set Tension knob setting to 3 at start. Adjust tension per instructions in the manual. 1.5/20 2/25 2/25...
4-2. Controls For Millermatic 211 Auto-Sett Models A. Spool Gun Operation On Millermatic 211 Auto-Sett Models Spool Gun/MIG Gun switch on Millermatic 211 Auto-Sett must be in Spool Gun position for spool gun to operate. Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual.
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B. Weld Parameter Chart For Millermatic 211 Auto−SetE Model Color parameter charts can be downloaded from www. MillerWelds.com or by ordering from a Miller distributor. OM-234 016 Page 28...
4-3. Controls For Millermatic Passport Plus Model A. Spool Gun Operation On Millermatic Passport Plus Model Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual. Valve Open valve on cylinder just before welding. Close valve on cylinder when finished welding.
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B. Weld Parameter Chart For Millermatic Passport Plus Model Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded. 1. Number on left of 2. Number on right slash is Voltage of slash is Wire Knob Setting.
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NOTE: Settings are approximate. Adjust as required. “---” Means not recommended. Thicker materials can be welded using proper technique, joint preparation and multiple passes. IMPORTANT: Match drive roll groove to diameter of wire being used. Set Tension knob setting to 3 at start. Adjust tension per instructions in the manual.
4-4. Controls For Renegade 180 Model A. Spool Gun Operation On Renegade 180 Model Spool Gun/MIG Gun switch on Renegade 180 must be in Spool Gun position for spool gun to operate. Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual.
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B. Weld Parameters For Renegade 180 Model Material Thickness Select Wire Type, Polarity, and Shielding Wire Size 20 ga 18 ga 16 ga 14 ga 1/8 in. 3/16 in. 1/4 in. 5/16 in. Shop Settings (Wall or Premise Power, 230 V 1 Ph) Aluminum 4043 (DCEP) 0.030 2.0/70...
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Maintain more often Disconnect power during severe conditions. before maintaining. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose...
5-2. Changing Drive Rolls 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 drive roll. To install drive roll: Slide drive roll onto shaft and se- cure with washer and screw.
5-3. Changing Liner Turn Off power at welding power source first. Nozzle Contact Tip Liner Remove and replace liner. Reinstall parts as shown. Tools Needed: Ref. 804 985-A 5-4. Troubleshooting Trouble Remedy No weld output; gun/feeder does not Place Power switch on welding power source in the On position (see welding power source Owner’s work.
5-5. GMAW (MIG) Aluminum Welding Hints Here are several hints to help you be more successful with your new aluminum feed system. MIG welding aluminum requires different techniques than MIG welding mild steel. A. Before You Start Welding The removal of lubricants from the aluminum base material may be necessary. Consult with your local welding distributor for their recommendation on aluminum cleaners.
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Maintain a 3/4 in. (19 mm) tip-to-work distance, and have the contact tip recessed approximately 1/8 in. inside the nozzle if possible. See Figure 5-2. Gas Nozzle Ç Ç Ç Ç Ç Ç Ç Ç Contact Tip To Work Ç Ç Ç Ç Contact Tube Recessed 1/8 Distance 3/4 in.
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LIMITED WARRANTY − Subject to the terms and conditions 90 Days — Parts Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its Accessory (Kits) 1-800-4-A-MILLER original retail purchaser that new Miller equipment sold after the...
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Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA 2010 Miller Electric Mfg. Co. 2010−01...