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Miller Electric Millermatic Vintage M-25 Gun Owner's Manual

Arc welding power source and wire feeder
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www.MillerWelds.com
Millermatic Vintage
And M-25 Gun
OM-1311
January 2003
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
R
153 490AA

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Summary of Contents for Miller Electric Millermatic Vintage M-25 Gun

  • Page 1 OM-1311 153 490AA January 2003 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic Vintage And M-25 Gun Visit our website at www.MillerWelds.com...
  • Page 2 Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. 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 orindividual catalog sheets.

  • 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 _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

  • 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 cause injury. 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: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

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

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Amperes Input at Rated Load Rated Welding Amperage Range Maximum Open- Output, 50 or 60 Hz, Single-Phase Output Output Circuit Voltage DC Circuit Voltage DC 200 V 230 V 460 V 575 V 200 A @ 28 Volts DC, 60% Duty Cycle 40 –...

  • Page 14: Welding Power Source Duty Cycle And Overheating

    2-3. Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.

  • Page 15: Installing Work Clamp

    2-5. Installing Work Clamp Work Cable Boot Slide boot onto work cable. Route cable out front panel opening from inside. Negative (–) Output Terminal Connect cable to terminal and cover connection with boot. Hardware Work Clamp Route cable through clamp handle and secure as shown.

  • Page 16: Installing Welding Gun

    2-7. Installing Welding Gun Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly. Tighten nut. Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. Ref.

  • Page 17: Setting Gun Polarity

    2-9. Setting Gun Polarity Polarity Changeover Label Always read and follow manufac- ture’s recommended polarity. Tools Needed: 3/4, 11/16 in Ref. 190 821-A 2-10. Positioning Jumper Links Check input voltage available at site. 230 VOLTS Jumper Links Access Door Open door. Jumper Link Label Jumper Links Location 460 VOLTS...

  • Page 18: Electrical Service Guide

    2-11. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker , Time-Delay Normal Operating Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) (18) (24) (37)

  • Page 19: Threading Welding Wire

    2-13. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: 4 in 6 in (102 mm) (150 mm) Open pressure assembly. Pull and hold wire;...

  • Page 20: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Front Panel Controls Controls For Standard Units Wire Speed Control The scale around the control is per- cent, not wire feed speed. Voltage Switch Use control and Voltage Range Se- lector (see Section 3-2) to set arc voltage.

  • Page 21: Center Baffle Controls

    3-2. Center Baffle Controls Wire Mode Switch For better control of wire speed use the Low position when wire speed is PRESS TO RESET between 90 and 670 ipm. Use the Full position when wire speed is be- tween 150 ipm and 1030 ipm. Voltage Range Selector DO NOT SWITCH Place switch in desired position.

  • Page 22: Weld Parameter Chart

    3-3. Weld Parameter Chart *Line voltage can affect weld output, settings on this chart are starting values only. You may need to adjust voltage and wire feed speed to optimize your settings. Input Line Parameter Voltage* Chart Settings Higher Weld Will Be e.g.
  • Page 23 Ref. 200 062 OM-1311 Page 19...

  • Page 24: Section 4 - Maintenance & Troubleshooting

    SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Maintain more often Y Disconnect power during severe conditions. before maintaining. 3 Months Clean And Repair Or Replace Tighten Replace Damaged Or Weld Cracked Unreadable Terminals Cables And Labels Cords 6 Months Remove drive roll and Blow Out Or carrier.

  • Page 25: Fuses F1 And F2

    4-3. Fuses F1 And F2 Y Turn Off unit, and disconnect input power. Fuse F1 (See Parts List For Rating) F1 protects the 115 volts ac winding of transformer T1. If F1 opens, all weld output stops and pilot light PL1 goes out.

  • Page 26: Cleaning Or Replacing Gun Liner

    4-6. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun first. 3/8 in Head tube Remove nozzle, contact tip, adapter, and wire outlet guide. 3/8 in Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Insert new liner.

  • Page 27: Replacing Switch And/Or Head Tube

    4-7. Replacing Switch And/Or Head Tube Y Disconnect gun first. Remove handle locking nut. Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure.

  • Page 28: Troubleshooting

    4-8. Troubleshooting Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-12). Reset circuit breaker CB1 (see Section 4-2). Replace fuse F1 and/or F2 (see Section 4-3). Replace building line fuse or reset circuit breaker if open (see Section 2-12). Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section 2-7 and/or 4-7).

  • Page 29: Section 5 - Electrical Diagram

    SECTION 5 – ELECTRICAL DIAGRAM 173 544-E Figure 5-1. Circuit Diagram For Welding Power Source OM-1311 Page 25...

  • Page 30: Section 6 - Parts List

    SECTION 6 – PARTS LIST Hardware is common and not available unless listed. Figure 6–2 – 2 Figure 6–4 – 7 Figure 6–5 – 19 Figure 6–6 – 20 800 930-E Figure 6-1. Main Assembly Item Dia. Part Mkgs. Description Quantity Figure 6-1.
  • Page 31 Item Dia. Part Mkgs. Description Quantity Figure 6-1. Main Assembly ..... . 203 481 PANEL, side LH ..........
  • Page 32 27 (Fig. 6–3) Hardware is common and not available unless listed. 800 931-E Figure 6-2. Baffle, Center w/Components OM-1311 Page 28...
  • Page 33 Item Dia. Part Mkgs. Description Quantity Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 2) ... . 058 427 RING, retaining spool ..........
  • Page 34 See Table 6-1 Drive Roll & Wire Guide Kits. Hardware is common and not available unless listed. 802 986-A Figure 6-3. Wire Drive And Gears Table 6-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire.
  • Page 35 Item Dia. Part Mkgs. Description Quantity Figure 6-3. Wire Drive And Gears (Fig 6-2 Item 28) ..... . 602 009 SCREW, .250-20 x 1.25 soc hd gr 8 .
  • Page 36 Hardware is common and not available unless listed. 802 288-A Figure 6-4. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 6-4. Panel, Rear w/Components (Fig 6-1 Item 7) ..... . 116 996 VALVE, 115 VAC 2way .
  • Page 37 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. Hardware is common and not available unless listed. 802 287 Figure 6-5. Panel, Front w/Components Item Dia.
  • Page 38 Ref. 800 792-C Figure 6-6. Exploded View Of Gun OM-1311 Page 34...
  • Page 39 Item Part Description Quantity Figure 6-6. Exploded View Of Gun (Fig 1 Item 20) ..200 258 NOZZLE, slip type .500 orf flush ..........
  • Page 40 Notes...
  • Page 41 Notes...
  • Page 42 Notes...
  • Page 43 Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold...

  • Page 44: Options And Accessories

    FAX: 44 (0) 1204-598066 www.MillerWelds.com 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. PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03...

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Millermatic vintageM-25

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