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Milweld H-10 Owner's Manual

Arc welding power source and wire feeder
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MW 140 Plus
And H-10 Gun
For Warranty Claims And Technical Support, Contact:
Milweld Inc., National Distributor
P.O. Box 338, Hortonville, WI 54944-0338
Tel 920-779-0916 Fax 920-779-0924
OM-219 316C
2006−10
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder

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Summary of Contents for Milweld H-10

  • Page 1 MW 140 Plus And H-10 Gun For Warranty Claims And Technical Support, Contact: Milweld Inc., National Distributor P.O. Box 338, Hortonville, WI 54944-0338 Tel 920-779-0916 Fax 920-779-0924 OM-219 316C 2006−10 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.
  • Page 4 TABLE OF CONTENTS SECTION 9 − MIG WELDING (GMAW) GUIDELINES 9-1. Typical MIG Process Connections 9-2. Typical MIG Process Control Settings 9-3. Holding And Positioning Welding Gun 9-4. Conditions That Affect Weld Bead Shape 9-5. Gun Movement During Welding 9-6. Poor Weld Bead Characteristics 9-7.

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

    DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 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 des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère 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.

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

    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. D Ne pas surcharger l’installation électrique −...

  • Page 12: Principales Normes De Sécurité

    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 Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Amperage Positive Output Do Not Switch While Welding SECTION 4 − SPECIFICATIONS 4-1. Specifications Rated Welding Amperage Output Range 90 A @ 19 Volts DC, 20% Duty Cycle 25 − 140 63 A @ 21 Volts DC, 20% Duty Cycle* Solid/ Stainless...

  • Page 14: Duty Cycle And Overheating

    4-2. Duty Cycle And Overheating 2 Minutes Welding Overheating OM-219 316 Page 10 Duty Cycle % 20% duty cycle at 90 amps 8 Minutes Resting Reduce Duty Cycle Minutes Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

  • Page 15: Volt-Ampere Curves

    4-3. Volt-Ampere Curves 30.0 25.0 20.0 15.0 10.0 RANGE3 RANGE2 RANGE1 100 110 120 130 140 150 160 Amperage The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.

  • Page 16: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Gun Be sure that gun end is tight against drive assembly. Exposed O-rings will cause shielding Incorrect gas leakage. Gun Not Seated 5-2. Installing Work Clamp Connection hardware must be tightened with proper tools. Do not just hand tighten hardware.

  • Page 17: Process/Polarity Table

    5-3. Process/Polarity Table Process Process GMAW − Solid wire with shield- DCEP − Reverse polarity ing gas FCAW − Self-shielding wire − DCEN − Straight Polarity no shielding gas 5-4. Changing Polarity Polarity Polarity Cable To Gun Connect to positive (+) out- put terminal Connect to negative (−) output terminal...

  • Page 18: Installing Gas Supply

    5-5. Installing Gas Supply DO NOT use Argon/Mixed gas regulator/flowmeter with CO shielding gas. See Parts List for optional gas regulator/flowmeter. Feedhead Pressure Assembly Open Tools Needed: 5/8, 1-1/8 in OM-219 316 Page 14 Argon Gas Or Mixed Gas Feedhead Pressure Assembly Closed Obtain gas cylinder and chain to running gear,...

  • Page 19: Selecting A Location And Connecting Input Power

    5-6. Selecting A Location And Connecting Input Power Y Do not move or operate unit 18 in (460 mm) where it could tip. 18 in (460 mm) Rating Label Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected time-delay fuses or circuit breaker is required.

  • Page 20: Installing Wire Spool And Adjusting Hub Tension

    5-7. Installing Wire Spool And Adjusting Hub Tension Installing 8 in (203 mm) Wire Spool Retaining ring used with 8 in (203 mm) spool only. Tools Needed: OM-219 316 Page 16 Installing 4 in (102 mm) Wire Spool Adapter used with 8 in (203 mm) spool only.

  • Page 21: Installing Contact Tip And Nozzle

    5-8. Installing Contact Tip And Nozzle Flux Nozzle Use with flux cored wire only. Narrow design allows access in tight spaces and provides better visibility of puddle during welding. Push nozzle over contact tip and adapter until it is seated onto adapter.

  • Page 22: Threading Welding Wire

    5-9. Threading Welding Wire Tools Needed: Open pressure assembly. Make sure feed roll is set to correct groove to match wire size (see Section 7-4). Tighten Be sure that wire is positioned in proper feed roll groove. Close and tighten pressure assembly, and let go of wire.

  • Page 23: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls Wire Speed Control Use control to select a wire feed speed. As Voltage switch setting increases, wire speed range also increases (see weld setting label in welding power source or NE PAS CHANGER DE PROCÉDÉ Section 6-2).

  • Page 24: Weld Parameter Chart

    6-2. Weld Parameter Chart OM-219 316 Page 20...
  • Page 25 217 618-A OM-219 316 Page 21...

  • Page 26: Section 7 − Maintenance &Troubleshooting

    SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. 7-2. Overload Protection 7-3. Drive Motor Protection Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again.

  • Page 27: Changing Drive Roll Or Wire Inlet Guide

    7-4. Changing Drive Roll Or Wire Inlet Guide Tools Needed: .030/.035 Groove Stamped .024 7-5. Replacing Gun Contact Tip Tools Needed: .023/.025 Groove Stamped .030/.035 Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching.

  • Page 28: Cleaning Or Replacing Gun Liner

    7-6. Cleaning Or Replacing Gun Liner Head Tube 8 mm Lay gun cable out straight before installing new liner. OM-219 316 Page 24 Y Disconnect gun from unit. Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. Blow out gun casing. Tools Needed: 8 mm / 10mm 10 mm...

  • Page 29: Replacing Switch And/Or Head Tube

    7-7. Replacing Switch And/Or Head Tube Remove handle locking nut. Secure head tube in vice. Loosen jam nut. Remove from vice and turn head tube out by hand. Hand-tighten head tube into cable connector. Tools Needed: 19 mm Y Turn Off welding power source /wire feeder and disconnect gun.

  • Page 30: Troubleshooting Table

    7-8. Troubleshooting Table Trouble Secure power cord plug in receptacle (see Section 5-6). No weld output; wire does not feed; fan does not run does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1). Reset welding power source supplementary protector (see Section 7-2).

  • Page 31: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM 230 952-A Figure 8-1. Circuit Diagram OM-219 316 Page 27...

  • Page 32: Section 9 − Mig Welding (Gmaw) Guidelines

    SECTION 9 − MIG WELDING (GMAW) GUIDELINES 9-1. Typical MIG Process Connections Regulator/ Flowmeter Gas Hose Shielding Gas OM-219 316 Page 28 Wire Feeder/ Power Source Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle.

  • Page 33: Typical Mig Process Control Settings

    9-2. 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. .035 in Wire Recommendation Size...

  • Page 34: Holding And Positioning Welding Gun

    9-3. 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. End View of Work Angle End View of Work Angle OM-219 316 Page 30...

  • Page 35: Conditions That Affect Weld Bead Shape

    9-4. 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. Short Short FILLET WELD ELECTODE EXTENSIONS (STICKOUT) Slow Push Perpendicular...

  • Page 36: Gun Movement During Welding

    9-5. 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. 9-6. Poor Weld Bead Characteristics 9-7.

  • Page 37: Troubleshooting − Excessive Spatter

    9-8. Troubleshooting − Excessive Spatter Possible Causes Wire feed speed too high. Voltage too high. Electrode extension (stickout) too long. Workpiece dirty. Insufficient shielding gas at welding arc. Dirty welding wire. Incorrect polarity. 9-9. Troubleshooting − Porosity Possible Causes Insufficient shielding gas at welding arc. Wrong gas.

  • Page 38: Troubleshooting − Lack Of Penetration

    9-11. Troubleshooting − Lack Of Penetration Lack of Penetration Good Penetration Possible Causes Improper joint preparation. Improper weld technique. Insufficient heat input. Incorrect polarity. 9-12. Troubleshooting − Incomplete Fusion Possible Causes Workpiece dirty. Insufficient heat input. Improper welding technique. 9-13. Troubleshooting − Burn-Through Possible Causes Excessive heat input.

  • Page 39: Troubleshooting − Waviness Of Bead

    9-14. Troubleshooting − Waviness Of Bead Possible Causes Welding wire extends too far out of nozzle. Unsteady hand. 9-15. Troubleshooting − Distortion Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input. Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

  • Page 40: Common Mig Shielding Gases

    9-16. 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 41 Problem Probable Cause Wire slipping in drive rolls. Welding arc not stable. Wrong size gun liner or contact tip. Incorrect voltage setting for selected wire feed speed on welding power source. Loose connections at the gun weld cable or work cable. Check and tighten all connections. Gun in poor shape or loose connection inside gun.

  • Page 42: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 803 716-B Figure 10-1. Main Assembly OM-219 316 Page 38...
  • Page 43 Item Dia. Part Mkgs....199 566 ....196 006 .
  • Page 44 Item Dia. Part Mkgs....207 079 ....211 338 .
  • Page 45 OPTIONAL To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. Figure 10-2. H-10 Gun Description Figure 10-2. H-10 Gun ..
  • Page 46 10-3. Optional Drive Rolls For All Feed Head Assemblies PART NO. 202 925 202 926 10-4. Options PART NO. 770 187 194 776 Small Running Gear/Cylinder Rack 212 492 144 108 220 747 222 874 NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order. OM-219 316 Page 42 WIRE DIAMETER INCHES (mm)

  • Page 47: Warranty

    Warranty Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, warrants to its original retail purchaser that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is...

  • Page 48: Owner's Record

    Owner’s Record Please complete and retain with your personal records. Model Name Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor for: Contact the Delivering Carrier to: PRINTED IN USA Serial/Style Number Welding Supplies and Consumables...

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Mw 140 plus

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