Miller Electric M-10 Gun Owner's Manual
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Miller Electric M-10 Gun Owner's Manual

Miller Electric M-10 Gun Owner's Manual

Om-1328
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Millermatic Passport
And M-10 Gun
OM-1328
2007−07
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And Wire
Feeder
R
File: MIG (GMAW)
220 073U
R

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Summary of Contents for Miller Electric M-10 Gun

  • Page 1 OM-1328 220 073U 2007−07 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic Passport And M-10 Gun File: MIG (GMAW) Visit our website at www.MillerWelds.com...
  • Page 2 ISO 9001:2000 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MIG WELDING (GMAW) GUIDELINES ..........8-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 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.
  • Page 6 D Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing D Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    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: California Proposition 65 Warnings

    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 &...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 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.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in- les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peu décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, ACCUMULATIONS des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. D Placer les bouteilles debout en les fixant dans un support station- D Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation.

  • Page 12: Proposition Californienne 65 Avertissements

    LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for Welding and Cut- 11 West 43rd Street, New York, NY 10036-8002 (téléphone :...
  • Page 14 OM-1328 Page 10...

  • Page 15: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS 3-1. Specifications Amperes Input at Rated Maximum Input Rated Load Out- Weight Overall Welding Open-Circuit Amperage Range Voltage put, 50/60 Hz, W/ Gun Dimensions Output Voltage DC Single-Phase 110 A @ 19.5 Volts DC, 20% Duty 23.1 2.69 2.66...

  • Page 16: Duty Cycle And Overheating

    3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. 115 VAC DUTY CYCLE If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.

  • Page 17: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Installing Work Clamp Insulating Sleeves Work Cable From Unit Slide one insulating sleeve over work cable before connecting to clamp. Work Clamp Screw Tools Needed: Work Clamp Tabs Bend tabs around work cable. Slide insulating sleeves over 3/8, 7/16 in...

  • Page 18: Process/Polarity Table

    4-3. Process/Polarity Table Cable Connections Process Process Polarity Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output ing gas put terminal terminal FCAW −...

  • Page 19: External Shielding Gas Supply

    4-6. External Shielding Gas Supply Shielding Gas Connector The shielding gas connector allows connecting an external shielding gas supply to the unit. Internal/External Transfer Switch The Internal/External Transfer switch allows changing between the internal or external shielding gas supply. Place switch in the External Gas Supply position.

  • Page 20: 115 Vac Input Power Requirements

    4-7. 115 VAC Input Power Requirements Connect input power cord to a 20 A individual branch circuit. If connecting to a circuit protected by fuses, use a time-delay fuse marked “D”. 4-8. Connecting 1-Phase Input Power For 230 VAC Installation must meet National and Local Codes −...

  • Page 21: Electrical Service Guide For 230 Vac

    4-9. Electrical Service Guide For 230 VAC Actual input voltage should not exceed 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not be available. 50/60 Hz Single Phase Input Voltage Input Amperes At Rated Output 17.7 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker...

  • Page 22: Selecting A Location And Connecting Input Power

    4-11. Selecting A Location And Connecting Input Power Do Not cut off power cord connector and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product warranty. Do not move or operate unit where it could tip.

  • Page 23: Installing 4 In (102 Mm) Wire Spool And Adjusting Hub Tension

    4-12. Installing 4 in (102 mm) Wire Spool And Adjusting Hub Tension Removing 8 in (203 mm) Spool Components Hub Nut Brake Adjust Knob Spring Nylon Washer Spool Hub Brake Washer Remove brake adjust knob and spring, and nylon washer. Remove and retain hub nut, spool hub, and brake washer.

  • Page 24: Installing And Threading Welding Wire

    4-13. Installing And Threading Welding Wire Installing Wire And Adjusting Hub Tension: Hold wire tightly to keep Retaining Nut it from unraveling. Hub Tension Adjustment Screw Remove retaining ring, and install spool so hub pin fits spool hole. Re- install retaining nut. Adjust tension screw so only a slight force is needed to turn spool.

  • Page 25: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls Voltage Control Turn control clockwise to increase voltage. The Voltage Control range from minimum to 7 is for 115 V input power. The full range from minimum to maximum (10) is for 230 V input power.

  • Page 26: Weld Parameter Chart

    5-2. Weld Parameter Chart OM-1328 Page 22...
  • Page 27 Ref. 220 579-B OM-1328 Page 23...

  • Page 28: Section 6 − Maintenance &Troubleshooting

    SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. 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 Every Months l Damaged Or Unreadable...

  • Page 29: Changing Drive Roll Or Wire Inlet Guide

    6-3. Changing Drive Roll Or Wire Inlet Guide 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. Drive Roll The drive roll consists of two differ- ent sized grooves.

  • Page 30: Cleaning Or Replacing Gun Liner

    6-5. Cleaning Or Replacing Gun Liner Tools Needed: Disconnect gun from unit. 8 mm / 10 mm Head Tube Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. 8 mm 10 mm Remove liner. Lay gun cable out straight before installing new liner.

  • Page 31: Replacing Switch And/Or Head Tube

    6-6. Replacing Switch And/Or Head Tube Turn Off welding power source and disconnect gun. Remove handle locking nut. Slide handle. Remove switch housing. Install new switch and connect leads (polarity is not important). Reas- semble in reverse order. If replacing head tube, continue to end of figure.

  • Page 32: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-1328 Page 28...
  • Page 33 219 992-H OM-1328 Page 29...

  • Page 34: Section 8 − Mig Welding (Gmaw) Guidelines

    SECTION 8 − MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. This unit can operate for either the internal or Disconnect both battery an external shielding gas supply. cables before welding on a vehicle.

  • Page 35: Typical Mig Process Control Settings

    8-2. 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. Low voltage: wire stubs into work Select voltage and wire feed High voltage: arc is unstable (spatter) speed from parameter chart...

  • Page 36: Holding And Positioning Welding Gun

    8-3. 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 37: Conditions That Affect Weld Bead Shape

    8-4. 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 38: Gun Movement During Welding

    8-5. 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 39: Troubleshooting − Excessive Spatter

    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. Electrode extension (stickout) too long.

  • Page 40: Troubleshooting − Excessive Penetration

    8-10. Troubleshooting − Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Good Penetration S-0639 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase travel speed. Wrong polarity.

  • Page 41: Troubleshooting − Burn-Through

    8-13. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. S-0640 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase and/or maintain steady travel speed. Wrong polarity.

  • Page 42: Common Mig Shielding Gases

    8-16. 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 43 Notes OM-1328 Page 39...

  • Page 44: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. Ref. 803 813-C Figure 9-1. Main Assembly OM-1328 Page 40...
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ....+220 656 CASE, machined 12L ..........
  • Page 46 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly (Continued) ....193 144 INSULATOR, output stud .........
  • Page 47 Ref. 804 095-A Figure 9-2. Wire Feed Drive Assembly Item Dia. Part Mkgs. Description Quantity 228 261 Figure 9-2 . Wire Feed Drive Assembly ....202 500 HOUSING, plastic drive motor .
  • Page 48 802 388-B Figure 9-3. M-10 Gun OM-1328 Page 44...
  • Page 49 Item Part Description Quantity Figure 9-3. M-10 Gun ....169 715 NOZZLE, slip type .500 orf flush ....... . .
  • Page 50 Notes...
  • Page 51 LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets, Cables, and Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after APT &...
  • Page 52 1-800-4-A-Miller www.MillerWelds.com 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. PRINTED IN USA 2007 Miller Electric Mfg. Co. 2007−01...

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