Miller Spoolmate 100 Series Owner's Manual
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Miller Spoolmate 100 Series Owner's Manual

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OM-234016G
2018−03
Processes
MIG (GMAW) Welding
Description
Wire Feeder Spool Gun
t
Spoolmate 100 Series
File: Wire Feeder
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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Summary of Contents for Miller Spoolmate 100 Series

  • Page 1 OM-234016G 2018−03 Processes MIG (GMAW) Welding Description Wire Feeder Spool Gun Spoolmate 100 Series File: Wire Feeder For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

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

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 8: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2018−01_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • 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, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 12: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 13: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications Approximate Wire Cooling Maximum Weld Circuit Wire Diameter Range Overall Dimensions Weight Feed Range Method Spool Size Rating .030 Thru .035 in. (0.8 Thru 0.9 mm) Length: 22.5 Volts, 135 6.0 lb (2.70 kg) 13 in.

  • Page 14: 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 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.
  • Page 15 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.

  • Page 16: Connecting Spool Gun To Millermatic 211 Auto-Set (907422, 907422001, 907422011)

    3-4. Connecting Spool Gun To Millermatic 211 Auto-Set (907422, 907422001, 907422011) 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.

  • Page 17: Connecting Spool Gun To Millermatic Passport Plus (907401)

    3-5. Connecting Spool Gun To Millermatic Passport Plus (907401) 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.

  • Page 18: Connecting Spool Gun To Renegade 180

    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.

  • Page 19: Connecting Spool Gun To Millermatic 141/ Millermatic 190

    3-7. Connecting Spool Gun To Millermatic 141/ Millermatic 190 Drive Assembly Gun Trigger Plug Gun Trigger Receptacle Route gun trigger plug through front panel. Insert plug into receptacle, and tighten threaded collar. Gun Securing Knob Gun End Polarity Changeover Terminal Block To make proper polarity connection, see welding power source Owner’s...

  • Page 20: Connecting Spool Gun To Millermatic 211 (907614)

    3-8. Connecting Spool Gun To Millermatic 211 (907614) Drive Assembly Gun Trigger Plug Gun Trigger Receptacle Route gun trigger plug through front panel. Insert plug into receptacle, and tighten threaded collar. Gun Securing Knob Gun End Polarity Changeover Terminal Block To make proper polarity connection, see welding power source Owner’s Manual .

  • Page 21: Connecting Spool Gun To Multimatic 215

    3-9. Connecting Spool Gun To Multimatic 215 Ref. 275167A Gun Securing Knob Loosen knob. Insert end of gun through Route trigger control cable through MIG opening in front panel until gun end gun hole. bottoms against gun block. Tighten Gun Block Connect plug on end of cable to four pin knob.

  • Page 22: Installing Wire Spool And Threading Welding Wire

    3-10. 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.

  • Page 23: 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 24 Match drive roll groove to diameter of wire being used. IMPORTANT: Set Tension knob setting to 3 at start. Adjust tension per instructions in the manual. Color parameter charts can be downloaded from www. MillerWelds.com or by ordering from a Miller distributor. OM-234 016 Page 20...
  • Page 25 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.
  • Page 26 Selecting Wire, Gas and Control Settings for Aluminum .030” (0.8 mm) 100% Argon Aluminum w/ Aluminum Opt. Spool Gun 4043ER .035” (0.9 mm) Color parameter charts can be downloaded from www. MillerWelds.com or by ordering from a Miller distributor. OM-234 016 Page 22...
  • Page 27 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 28 .030” (0.8 mm) #000067 .035 − .045” (0.9 − 1.2 mm) #194012 .035” (0.9 mm) #000068 .045” (1.2 mm) #000069 Color parameter charts can be downloaded from www. MillerWelds.com or by ordering from a Miller distributor. OM-234 016 Page 24...
  • Page 29 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 30: Controls For Millermatic 211 Auto-Sett Models (907422, 907422001, 907422011)

    4-2. Controls For Millermatic 211 Auto-Sett Models (907422, 907422001, 907422011) A. Spool Gun Operation On Millermatic 211 Auto-Sett Models (Only Manual Setup can be used on this model) Spool Gun/MIG Gun switch on Millermatic 211 Auto-Sett must be in Spool Gun position for spool gun to operate.
  • Page 31 Notes OM-234 016 Page 27...
  • Page 32 B. Weld Parameter Chart For Millermatic 211 Auto−SetE Models (907422, 907422001, 907422011) Color parameter charts can be downloaded from www. MillerWelds.com or by ordering from a Miller distributor. OM-234 016 Page 28...
  • Page 33 OM-234 016 Page 29...

  • Page 34: Controls For Millermatic Passport Plus Model

    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.
  • Page 35 Notes OM-234 016 Page 31...
  • Page 36 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.
  • Page 37 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 38: Controls For Renegade 180 Model

    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.
  • Page 39 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...

  • Page 40: Controls For Millermatic 141 Model

    4-5. Controls For Millermatic 141 Model (907612) A. Spool Gun Operation On Millermatic 141 Model (Only Manual Setup can be used on this model) ** See weld parameter chart for Auto-Set instructions. ** Multiple passes required for solid wire Rear View 274600-A / 267833-A Shielding Gas Cylinder Voltage/Material Thickness Control...
  • Page 41 B. Millermatic 141 Auto−Set Feature The Auto−Set feature is not intended to be used with the Spoolmate 100 on this model. ** See weld parameter chart for Auto-Set instructions. ** Multiple passes required for solid wire 274600-A Wire Speed/Wire Diameter Control Auto-Set Light Voltage/Material Thickness Control Adjust the Voltage/Material Thickness...
  • Page 42 D. Weld Parameter Chart For Millermatic 141 Model 267 700-C OM-234 016 Page 38...
  • Page 43 E. Weld Parameters For Millermatic 141 Ref. 267 700-C OM-234 016 Page 39...

  • Page 44: Controls For Millermatic 190 Model (907613)

    4-6. Controls For Millermatic 190 Model (907613) A. Spool Gun Operation On Millermatic 190 Model (Only Manual Setup can be used on this model) Rear View 274602-A / 270208-B Shielding Gas Cylinder Wire Speed/Wire Diameter Control Power Light For shielding gas connections, see power Turn control clockwise inside white scale Power light illuminates when the unit is source Owner’s Manual.
  • Page 45 B. Millermatic 190 Auto-Set Feature The Auto−Set feature is not intended to be used with the Spoolmate 100 on this model. 274602-A Wire Speed/Wire Diameter Control Auto-Set Light Voltage/Material Thickness Control Adjust the Voltage/Material Thickness To turn Auto-Set on, turn the Wire Speed/ control knob to the desired steel material The Auto-Set light illuminates indicating Wire Diameter control knob to the desired...
  • Page 46 D. Weld Parameter Chart For Millermatic 190 267 702-D OM-234 016 Page 42...
  • Page 47 E. Weld Parameters For Millermatic 190 Ref. 267 702-D OM-234 016 Page 43...

  • Page 48: Controls For Millermatic 211 Model (907614)

    4-7. Controls For Millermatic 211 Model (907614) A. Spool Gun Operation For Millermatic 211 (Manual Setup) Rear View 274604-A / 270208-A Shielding Gas Cylinder Process Select Control Over Temperature Light If unit overheats, light turns on and output For shielding gas connections, see weld- Turn control to select desired weld stops.
  • Page 49 B. Millermatic 211 Auto-Set Feature (Using Auto−Set) 274604-A Process Select Control Auto-Set LED Voltage/Material Thickness Control Turn control to select process, material, Adjust the Voltage/Material Thickness The Auto-Set light illuminates indicating and type of shielding gas. control knob to the desired steel material Auto-Set is on.
  • Page 50 D. Weld Parameter Chart For Millermatic 211 267705A OM-234 016 Page 46...
  • Page 51 E. Weld Parameters For Millermatic 211 Ref. 267705A OM-234 016 Page 47...

  • Page 52: Controls For Multimatic 215 Model (907693)

    4-8. Controls For Multimatic 215 Model (907693) A. Spool Gun Operation On Multimatic 215 Model Ref. 271491A / 275178A Shielding Gas Cylinder Spoolmate Motor Calibration procedure. Material Thickness Buttons For shielding gas connections, see welding Press the Plus (+) or Minus (−) button to Auto−Set Button power source Owner’s Manual.
  • Page 53 Notes OM-234 016 Page 49...
  • Page 54 B. Weld Parameter Chart For Multimatic 215 Model (120 Volt Input Power) Wire Drive Work Work Wire Drive Lead Lead Lead Lead Ref. 272942-C OM-234 016 Page 50...
  • Page 55 C. Weld Parameter Chart For Multimatic 215 Model (240 Volt Input Power) Wire Drive Work Work Wire Drive Lead Lead Lead Lead 18.0/310 Ref. 272942-C OM-234 016 Page 51...

  • Page 56: Section 5 − Maintenance & Troubleshooting

    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...

  • Page 57: Changing Drive Rolls

    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.

  • Page 58: Changing Liner

    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.

  • Page 59: 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 60 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.

  • Page 61: Section 6 − Electrical Diagrams

    SECTION 6 − ELECTRICAL DIAGRAMS − − 3 to 18 VDC 186 451 Figure 6-1. Circuit Diagram For Spoolmate OM-234 016 Page 57...
  • Page 62 Figure 6-2. Circuit Diagram For Millermatic 140/180 OM-234 016 Page 58...
  • Page 63 234 419-B OM-234 016 Page 59...

  • Page 64: 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 60...
  • Page 65 Item Dia. Part Quantity Mkgs. Description Figure 7-1. Complete Assembly ... . 186416 TRIGGER SWITCH ..........
  • Page 66 Notes...
  • Page 67 Effective January 1, 2018 (Equipment with a serial number preface of MJ or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 68 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 2018 Miller Electric Mfg. LLC 2018−01...

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