Miller Spoolmate 200 Owner's Manual
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Miller Spoolmate 200 Owner's Manual

W/heavy duty barrel
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OM-243 762E
2015−07
Processes
MIG (GMAW) Welding
Description
Feeder Gun
Spoolmate 200
R
w/Heavy Duty Barrel
File: MIG (GMAW)
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller Spoolmate 200

  • Page 1 OM-243 762E 2015−07 Processes MIG (GMAW) Welding Description Feeder Gun Spoolmate 200 w/Heavy Duty Barrel File: MIG (GMAW) Visit our website at 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 2013−09 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 Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • 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 injure. 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 Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2013−09 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 Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements câble pour le procédé...

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

    LES BOUTEILLES peuvent exploser DES PIECES DE METAL ou DES si elles sont endommagées. SALETES peuvent provoquer des blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser.
  • Page 12 LES CHARGES ÉLECTROSTATI- RAYONNEMENT HAUTE QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque cuits imprimés. provoquer des interférences. D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi- pements de radio−navigation et de com- D Utiliser des pochettes et des boîtes antista-...

  • Page 13: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres formations congénitales et, dans certains cas, des cancers.
  • Page 14 OM-243 762 Page 10...

  • Page 15: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications Approximate Cooling Maximum Spool Weld Circuit Overall Wire Feed Wire Diameter Range Weight Method Size Rating Dimensions Range .030 Thru .035 in. Length: (0.8 Thru 0.9 mm) 100 Volts, 160 15-1/4 in. (387 mm) Aluminum Wire 50 To 800 ipm Width:...

  • Page 16: Connecting Spool Gun To Millermatic 212 Auto-Set

    3-2. Connecting Spool Gun To Millermatic 212 Auto-Set Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Weld Cable Spoolmate 200 Shielding Gas Hose Route weld cable through opening in front panel. Route gas hose along side panel or...

  • Page 17: Opening Cover

    3-3. Opening Cover Thumbscrew Cover Loosen thumbscrew and rotate cover open. 243 736-C 3-4. Installing Wire Spool And Threading Welding Wire Cover Canister Thumbscrew (Cover) Loosen thumbscrew, and rotate cover open. Wire Spool Loosen wire from spool, cut off bent wire, and pull 6 in (150 mm) of wire off spool.

  • Page 18: Installing Gas Supply

    3-5. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, other stationary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve.

  • Page 19: Adjusting Drive Roll And Spool Brake Pressure

    3-6. Adjusting Drive Roll And Spool Brake Pressure Cover Thumbscrew Loosen thumbscrew and rotate cover open. Spool Cut welding wire off at contact tip. Retract wire onto spool and secure. Spool Brake Thumbnut Grasp spool in one hand and turn while adjusting spool brake thumb- nut.

  • Page 20: Installing Optional Barrels

    3-7. Installing Optional Barrels 244 690-A / 244 692-B / 244 688-B / 273108-A Curved Barrel Replace outlet guide pin and jump liner. In- Turn Off and disconnect input stall lock washer and nut. power. Liner Tighten nut and set screw. Contact Adapter Guide Pin Install liner as shown.

  • Page 21: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls Trigger Press trigger to energize welding power source contactor (if applica- ble), start shielding gas flow, and begin wire feed. For shielding gas preflow and post- flow, lightly press trigger before and after welding. Wire Speed Control Use control to adjust wire feed speed.

  • Page 22: Section 5 − Maintenance & Troubleshooting

    SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Damaged Or Unreadable l Repair Or Replace...

  • Page 23: Replacing Head Tube Liner

    5-3. Replacing Head Tube Liner The standard head tube liner will accommodate wire diameters of .023 thru .035 (0.8 thru 0.9 mm) wire size. Old Style Liner Head Tube Loosen nut and remove head tube from gun. Liner Pull liner out of gun. Insert liner into gun and reinstall head tube onto gun.

  • Page 24: Gun Drive Assembly Maintenance

    5-4. Gun Drive Assembly Maintenance Retract wire onto spool. Setscrew Drive Roll Use wire brush to clean drive roll. Install drive roll with desired groove down, and turn drive roll so one set- screw faces flat side of shaft. Bearing Use wire brush to clean bearing.

  • Page 25: Replacing Inlet Guide

    5-5. Replacing Inlet Guide Cover Pressure Roll Assembly Cut off welding wire where it enters pressure roll assembly area. Nozzle Pull wire out nozzle end. Thumbscrew Loosen thumbscrew and rotate cover open. Wire Spool Spool Brake Thumbnut Loosen thumbnut, retract wire onto spool, secure, and remove spool.

  • Page 26: Replacing Diffuser

    5-6. Replacing Diffuser Turn Off welding power source. Nozzle Contact Tip To remove, see Section 5-2. Phillips Head Screw Liner Housing Liner Loosen screw and remove liner housing and liner. Diffuser Remove diffuser and replace. Tools Needed: Ref. 244 693-B 5-7.

  • Page 27: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 244 645-A Figure 6-1. Circuit Diagram For Gun/Feeder OM-243 762 Page 23...

  • Page 28: Section 7 − Parts List

    SECTION 7 − PARTS LIST All hardware is contained in hardware kit P/N 244 657. 243 742-C Figure 7-1. Complete Assembly OM-243 762 Page 24...
  • Page 29 ..247 367 Kit, Liner W/Outlet Guide Spoolmate 200 HD ......
  • Page 30 Hardware is common and not available unless listed. 244 691-B Figure 7-2. Optional 9” Barrel Item Dia. Part Mkgs. Description Quantity 300 592 Figure 7-2. Optional 9” Barrel ... . . 186 405 Nozzle .
  • Page 31 Hardware is common and not available unless listed. 243 741-C Figure 7-3. Optional 4.5” Barrel Item Dia. Part Mkgs. Description Quantity 243 385 Figure 7-3. Optional 4.5” Barrel ... . . 186 419 Contact Tip 0.030”...
  • Page 32 Hardware is common and not available unless listed. 244 689-B Figure 7-4. Optional Curved Barrel Item Dia. Part Mkgs. Description Quantity 300 591 Figure 7-4. Optional Curved Barrel ... . . 198 429 Nozzle .
  • Page 33 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in)
  • Page 34 Notes Ref. AWS/ANSI D1.1 WELD JOINT TYPES GROOVE FILLET WELD POSITION: FLAT BUTT T−JOINT HORIZONTAL BUTT T−JOINT VERTICAL BUTT T−JOINT OVERHEAD BUTT T−JOINT Ref. 804 248-A − 30 −...
  • Page 35 Effective January 1, 2015 (Equipment with a serial number preface of MF 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 36 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 2015 Miller Electric Mfg. Co. 2015−01...

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