Miller Electric OM-234 016D Owner's Manual
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Miller Electric OM-234 016D Owner's Manual

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OM-234 016D
2007−11
Processes
MIG (GMAW) Welding
Description
Wire Feeder Spool Gun
Spoolmate 100 Series
File: Wire Feeder
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller Electric OM-234 016D

  • Page 1 OM-234 016D 2007−11 Processes MIG (GMAW) Welding Description Wire Feeder Spool Gun Spoolmate 100 Series File: Wire Feeder 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. Symbol Usage ............... 1-2.

  • Page 5: Errata Sheet

    Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. OM-234 016D Ref. 804 984-A / Ref. 805 390-A / Ref. 801 987 Polarity Changeover Terminal Block To make proper polarity connection, see welding power source Owner’s Manual.
  • Page 6 CHANGES TO SECTION 4 − OPERATION Add Section 4-4. Controls For Millermatic 211 Auto-Sett Models Add Section 4-4A. Spool Gun Operation On Millermatic 211 Auto-Sett Models (See Page 3) Add Section 4-4B. Weld Parameter Chart For Millermatic 211 Auto-Sett Model (See Pages 4 And 5) OM-234 016 Page 3...
  • Page 7 OM-234 016 Page 4 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. Valve Open valve on cylinder just before welding.
  • Page 8 Color parameter charts can be downloaded from www. MillerWelds.com or by ordering from a Miller distributor. OM-234 016 Page 5...
  • Page 9 239 992-B OM-234 016 Page 6...

  • Page 10: 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 11 OM-234 016 Page 2 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 12: 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 13: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other...

  • Page 14: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 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 l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
  • Page 15 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

  • Page 16: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    ACCUMULATIONS risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux.

  • Page 17: Proposition Californienne 65 Avertissements

    LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures.

  • Page 18: 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 Internet : 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 19 OM-234 016 Page 10...

  • Page 20: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications Approximate Wire Wire Diameter Range Feed Range Millermatic 140 AutoSet: 5 To 365 ipm .030 Thru .035 in (0.8 Thru 0.9 mm) (0.13 To 9.27 mpm) Aluminum Wire Millermatic 140: 5 To 435 ipm Or Flux Cored Wire (0.13 To 11.05 mpm) .023 Thru 035 in...

  • Page 21: Connecting Spool Gun To Millermatic 140/180 Models

    3-3. Connecting Spool Gun To Millermatic 140/180 Models A. Installing Optional Spool Gun Switch In Millermatic 140/180 Models Tools Needed: 1/4, 5/16 in 9/16 in OM-234 016 Page 12 Renegade Passport Plus Models: Discard switch assembly; unit pre−wired for spool gun option. Go to Section 3-4 or 3-5.
  • Page 22 B. Connecting Spool Gun To Millermatic 140/180 Be sure that gun end is tight against drive assembly. Incorrect Exposed O-rings will cause shielding Gun Not Seated Correct Gun Fully Seated gas leakage. Drive Assembly Spool Gun Gun Securing Knob Gun End Loosen thumbscrew.

  • Page 23: Connecting Spool Gun To Millermatic Passport Plus

    3-4. Connecting Spool Gun To Millermatic Passport Plus Be sure that gun end is tight against drive assembly. Incorrect Exposed O-rings will cause shielding Gun Not Seated gas leakage. OM-234 016 Page 14 Correct Gun Fully Seated Drive Assembly Spool Gun Gun Securing Knob Gun End Loosen thumbscrew.

  • Page 24: Connecting Spool Gun To Renegade 180

    3-5. 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.

  • Page 25: Installing Wire Spool And Threading Welding Wire

    3-6. Installing Wire Spool And Threading Welding Wire Tools Needed: Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm). Install contact tip and nozzle. Reinstall spool cover and thumb screw.

  • Page 26: Section 4 − Operation

    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.
  • Page 27 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. .024” Auto−Set* WELD WIRE .030” DIAMETER M A T ERI A L T H o − (DCEP) (DCEP) (DCEN)
  • Page 28 Manual Setup Refer to chart below to select Voltage and Wire Speed based on thickness of metal being welded. M A TER I A L T H I o − 2/40 3/50 3/50 4/65 4.5/70 2/32 3/40 3/40 4/45 5/55 4/45 5/60 5.5/65...
  • Page 29 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 slash is Voltage Knob Setting. (Example: 4.5/55) Solid Wire ER70S−6...
  • Page 30 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.

  • Page 31: Stainless Steel

    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 slash is Voltage Knob Setting. (Example: 4.5 / 55) (DCEP) (DCEP)
  • Page 32 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...
  • Page 33 Notes OM-234 016 Page 24...

  • Page 34: Controls For Millermatic Passport Plus Model

    4-2. Controls For Millermatic Passport Plus Model A. Spool Gun Operation On Millermatic Passport Plus Model MATERIAL SELECT 115V RANGE Aluminum (Spool Gun) Stainless Steel RANG Mild Steel Shielding Gas Cylinder For shielding gas connections, see welding power source Owner’s Manual.
  • Page 35 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 slash is Voltage Knob Setting. 4.5 / 55) (Example: Steel Solid Wire CO 2...
  • Page 36 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.

  • Page 37: Controls For Renegade 180 Model

    4-3. Controls For Renegade 180 Model A. Spool Gun Operation On Renegade 180 Model OM-234 016 Page 28 sb5.1* 6/92 − S-0621-C / Ref. 804 755-B / Ref. 804 986-A / 804 476-C Spool Gun/MIG Gun switch on Renegade 180 must be in Spool Gun position for spool gun to operate.
  • Page 38 B. Weld Parameters For Renegade 180 Model Select Wire Type, Polarity, and Shielding Aluminum 4043 (DCEP) 100% Argon Shielding Gas Aluminum 4043 (DCEP) 100% Argon Shielding Gas Notes Wire Size 20 ga 18 ga 16 ga Shop Settings (Wall or Premise Power, 230 V 1 Ph) 0.030 2.0/70 2.0/70...

  • Page 39: Section 5 − Maintenance & Troubleshooting

    SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent l Unreadable Labels ~ Weld Terminals Every Months nl Cords nl Gun Cables Every Months ~ Drive Rolls ~ Inside Unit OM-234 016 Page 30 Disconnect power...

  • Page 40: Changing Drive Rolls

    5-2. Changing Drive Rolls It may be necessary to remove drive roll side of gun case to change lower drive roll. Tools Needed: 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...

  • Page 41: Changing Liner

    5-3. Changing Liner Tools Needed: 5-4. Troubleshooting Trouble 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. Manual). Check Spool Gun/MIG Gun switch for correct position. Erratic weld output.

  • Page 42: Gmaw (Mig) Aluminum Welding Hints

    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.

  • Page 43: Common Problems/Troubleshooting

    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. Contact Tube Recessed 1/8 in. (3.2 mm) Inside The Nozzle Figure 5-2. Contact Tube Position And Tip-To-Work Distance Avoid large weave beads on aluminum.

  • Page 44: Section 6 − Electrical Diagrams

    SECTION 6 − ELECTRICAL DIAGRAMS 186 451 Figure 6-1. Circuit Diagram For Spoolmate OM-234 016 Page 35...
  • Page 45 Figure 6-2. Circuit Diagram For Millermatic 140/180 OM-234 016 Page 36...
  • Page 46 234 419-B OM-234 016 Page 37...

  • Page 47: Section 7 − Parts List

    SECTION 7 − PARTS LIST Hardware is common and not available unless listed. 804 988-A Figure 7-1. Complete Assembly OM-234 016 Page 38...
  • Page 48 Item Dia. Part Mkgs... . 186 416 ....186 418 ....209 177 .
  • Page 49 Notes...
  • Page 50 Notes...
  • Page 51 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 52: Owner's Record

    For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

This manual is also suitable for:

Spoolmate 100 series

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