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Milweld XLT 185 Owner's Manual

Arc welding power source and wire feeder
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XLT 185
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-230 832A
2007−02
Processes
Gas Metal Arc (MIG) Welding
Flux Cored Arc (FCAW)
Welding
Description
Arc Welding Power Source and Wire
Feeder

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Summary of Contents for Milweld XLT 185

  • Page 1 XLT 185 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-230 832A 2007−02 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding...

  • 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 130 A @ 21.5 Volts DC, 30% Duty Cycle At 60 Hz Input − 20% 25 −...

  • Page 14: Duty Cycle And Overheating

    4-2. Duty Cycle And Overheating 3 Minutes Welding Overheating 4-3. Volt-Ampere Curves OM-230 832 Page 10 60 70 80 Duty Cycle % 30% duty cycle at 130 amps, 60 Hz 20% duty cycle at 130 amps, 50 Hz 7 Minutes Resting Minutes 100 110 120 130 140 150 160 170 180 190 200 Amperage...

  • Page 15: 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 Correct Gun Fully Seated Drive Assembly Gun Securing Thumbscrew Gun End Loosen thumbscrew.

  • Page 16: Installing Work Clamp

    5-2. Installing Work Clamp Connection hardware must be tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating of the work clamp. Tools Needed: 7/16 in 7/16 in OM-230 832 Page 12 Work Cable From Unit Work Clamp...

  • 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 Connection hardware must be tightened with proper tools. Do not just hand tighten hardware.

  • 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-230 832 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 18 in (457 mm) of space for airflow Y Do not move or operate unit where it could tip. =GND/PE Earth Ground 230 VAC, 1 Y Special installation may be required where gasoline or volatile liquids are present −...

  • Page 20: Electrical Service Guide

    5-7. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG Reference: 1999 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.

  • Page 21: Installing Contact Tip And Nozzle

    5-9. 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

    5-10. 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 drive roll groove and wire is laying in the 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 Section 6-2, as applicable). Power Switch Voltage Switch The higher the selected number, the...

  • Page 24: Weld Parameter Chart For 230 Vac Model

    6-2. Weld Parameter Chart For 230 VAC Model Flux Cored E71T−11 “Set Polarity for (DCEN)” Solid Wire ER70S−6 “Set Polarity for (DCEP)” Solid Wire ER70S−6 “Set Polarity for (DCEP)” Stainless Steel “Set Polarity for (DCEP)” Aluminum** “Set Polarity for (DCEP)” OM-230 832 Page 20 Good for windy or outdoor applications...
  • Page 25 1/40 2/40 4/60 1/35 2/40 3/50 1/25 3/30 3/50 4/60 5/80 2/50 3/50 5/60 4/40 5/40 5/50 3/35 5/40 5/60 4/40 5/40 5/50 5/40 3/25 4/25 3/40 4/50 6/60 3/35 4/30 5/35 3/35 4/30 5/40 2/90 6/90 2 / 100 6/90 5/40 6 / 40*...

  • 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-230 832 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 No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 5-6). 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 Notes OM-230 832 Page 27...

  • Page 32: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-230 832 Page 28...
  • Page 33 228 180-A OM-230 832 Page 29...

  • Page 34: Section 9 − Mig Welding (Gmaw) Guidelines

    SECTION 9 − MIG WELDING (GMAW) GUIDELINES 9-1. Typical MIG Process Connections Regulator/ Flowmeter Wire Feeder/ Power Source Gas Hose Shielding OM-230 832 Page 30 Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle.

  • Page 35: 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 36: 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-230 832 Page 32...

  • Page 37: 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 38: 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 39: 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 40: 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 41: 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. 9-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used.

  • Page 42: Troubleshooting Guide For Semiautomatic Welding Equipment

    9-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Too little pressure on wire feed rolls. Wire feed motor operates, but wire does not feed. wire does not feed. Incorrect wire feed rolls. Wire spool brake pressure too high. Restriction in the gun and/or assembly.
  • Page 43 Notes OM-230 832 Page 39...

  • Page 44: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 804 624-A Figure 10-1. Main Assembly OM-230 832 Page 40...
  • Page 45 Item Dia. Part Mkgs....199 566 ....196 006 .
  • Page 46 Item Dia. Part Mkgs....196 574 ....228 400 .
  • Page 47 Item Part 195 957 ....169 715 ....226 190 .
  • Page 48 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 195 957 212 492 144 108 NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order. OM-230 832 Page 44 WIRE DIAMETER INCHES (mm)
  • Page 49 Notes...
  • Page 50 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
  • Page 51 Warranty Effective January 1, 2007 (Equipment with a serial number preface of “LH” 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 52: 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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