Miller Millermatic 140 Owner's Manual
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Miller Millermatic 140 Owner's Manual

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Millermatic 140,
140 Auto−Set , And 180
And M-10 Gun
OM-225 311A
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
R
™
File: MIG (GMAW)
2006−10

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  • Page 1 OM-225 311A 2006−10 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic 140, 140 Auto−Set , And 180 ™ And M-10 Gun Visit our website at File: MIG (GMAW) 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 4 TABLE OF CONTENTS SECTION 8 − MIG WELDING (GMAW) GUIDELINES ..........8-1.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • 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 visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.

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

    D Read Owner’s Manual before using or servic- support unit. ing unit. D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement long enough to extend beyond opposite side of parts. unit.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 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- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.

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

    D Utiliser un équipement de levage de capacité D Utiliser uniquement des pièces de rechange suffisante pour lever l’appareil. Miller/Hobart. D En utilisant des fourches de levage pour déplacer l’unité, s’assu- rer que les fourches sont suffisamment longues pour dépasser du côté...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.org).

  • Page 13: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS 3-1. Specifications A. 115 VAC Model Amperes Input at Maximum Rated Welding Rated Load Out- Weight Overall Amperage Range Open-Circuit Output W/ Gun Dimensions put 115 V, 60 Hz, Voltage DC Single-Phase Length: 17-1/2 in 90 A @ 18 (444 mm) Volts DC, 20% Duty Cycle...

  • Page 14: Duty Cycle And Overheating

    3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) A. 115 VAC opens, output stops, and cooling Model fan runs. Wait fifteen minutes for unit to cool.

  • Page 15: Volt-Ampere Curves

    3-3. Volt-Ampere Curves The volt-ampere curves show the A. 115 VAC Model minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. M A X M IN A M PE R A G E B.

  • Page 16: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Installing Welding Gun Drive Assembly Gun Securing Knob Gun End Loosen knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. Gun Trigger Plug Insert into receptacle, and tighten threaded collar. Close door.

  • Page 17: Work Cable Routing Inside Unit

    4-3. Work Cable Routing Inside Unit Work Cable Output Terminal Block Insert work cable through opening in front panel and route along back of front panel to output terminal block. Close door. Ref. 802 982-A 4-4. Process/Polarity Table Cable Connections Process Process Polarity...

  • Page 18: Installing Gas Supply

    4-6. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, other stationary support so cylinder cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter with CO shielding gas. See Parts List for optional Cylinder Valve gas regulator/flowmeter and hose.

  • Page 19: Selecting A Location And Connecting Input Power For 115 Vac Model

    4-7. Selecting A Location And Connecting Input Power For 115 VAC Model Rating Label Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected by time-delay 18 in fuses or circuit breaker is required. (460 mm) Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m).

  • Page 20: Selecting A Location And Connecting Input Power For 230 Vac Model

    4-8. Selecting A Location And Connecting Input Power For 230 VAC Model Y Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. Y Disconnect and lockout/tag- Y Do not move or operate unit out input power before con- necting input conductors from where it could tip.

  • Page 21: Electrical Service Guide For 230 Vac Model

    4-9. Electrical Service Guide For 230 VAC Model 60 Hz Single Phase Input Voltage Input Amperes At Rated Output 21.7 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker , Time-Delay Normal Operating Min Input Conductor Size In AWG Max Recommended Input Conductor Length In Feet (Meters) (19) Min Grounding Conductor Size In AWG Reference: 2005 National Electrical Code (NEC) (including article 630)

  • Page 22: Threading Welding Wire

    4-11. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 4 in (102 mm) 6 in (150 mm) Open pressure assembly.

  • Page 23: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls For 115 VAC Model w/Auto-SetE 227 748-C Wire Speed Control Power Switch provide the appropriate wire feed speed for the material thickness selected using the Turn control clockwise inside white scale Over Temperature Light Voltage control (see Section 5-4).

  • Page 24: Controls For 115 Vac Model

    5-2. Controls For 115 VAC Model ® 115V Wire Welder Welds 24 gauge to 3/16" Mild Steel OVER TEMP POWER TRIGGER 225 226-C Wire Speed Control Voltage Control Power Switch Turn control clockwise to increase wire Turn control clockwise to increase voltage Over Temperature Light feed speed.

  • Page 25: Controls For 230 Vac Model

    5-3. Controls For 230 VAC Model 230V Wire Welder Welds 24 gauge to 5/16" Mild Steel TRIGGER OVER TEMP POWER 225 227-C Wire Speed Control Voltage Control Power Switch Turn control clockwise to increase wire Turn control clockwise to increase voltage Over Temperature Light feed speed.

  • Page 26: Weld Parameter Chart For 115 Vac Model W/Auto−Sett

    5-4. Weld Parameter Chart For 115 VAC Model w/Auto−SetE AUTO−SETt − SIMPLE SETUP FOR WELDING MILD STEEL Example: .030" diameter wire, welding 18 ga. material. Activate AUTO−SETt by selecting the diameter of the welding wire with the WIRE SPEED knob. AUTO−SETt light comes on.
  • Page 27 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 / M A T ERIA L T H I C 2.

  • Page 28: Weld Parameter Chart For 115 Vac Model W/Factory Set

    5-5. Weld Parameter Chart For 115 VAC 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 2. Number on right slash is Voltage of slash is Wire Knob Setting.
  • 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.

  • Page 30: Weld Parameter Chart For 115 Vac Model W/Wire Speed Tracking Mode

    5-6. Weld Parameter Chart For 115 VAC Model w/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 2. Number on right slash is Voltage of slash is Wire Knob Setting.
  • Page 31 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 32: Weld Parameter Chart For 230 Vac Model W/Factory Set

    5-7. Weld Parameter Chart For 230 VAC 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 2. Number on right slash is Voltage of slash is Wire Knob Setting.
  • Page 33 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 34: Weld Parameter Chart For 230 Vac Model W/Wire Speed Tracking Mode

    5-8. Weld Parameter Chart For 230 VAC Model w/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 2. Number on right slash is Voltage of slash is Wire Knob Setting.
  • Page 35 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. 2.5/28 4/50 4.5/70...

  • Page 36: Section 6 − Maintenance &Troubleshooting

    SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Unreadable Labels...

  • Page 37: Changing Drive Roll Or Wire Inlet Guide

    6-4. Changing Drive Roll Or Wire Inlet Guide Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place. Drive Roll The drive roll consists of two differ- ent sized grooves.

  • Page 38: Cleaning Or Replacing Gun Liner

    6-6. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit. 8 mm / 10 mm Head Tube Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. 8 mm 10 mm Remove liner. Lay gun cable out straight before installing new liner.

  • Page 39: Replacing Switch And/Or Head Tube

    6-7. Replacing Switch And/Or Head Tube Y Turn Off welding power source /wire feeder and disconnect gun. Remove handle locking nut. Slide handle. Remove switch housing. Install new switch and connect leads (polarity is not important). Reas- semble in reverse order. If replacing head tube, continue to end of figure.

  • Page 40: Troubleshooting Table

    6-8. Troubleshooting Table Trouble Remedy Secure power cord plug in receptacle (see Section 4-7 or 4-8). No weld output; wire does not feed; fan does not run does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 5-2, 5-1, or 5-3).

  • Page 41: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM 229 578-A Figure 7-1. Circuit Diagram For 115 VAC Model w/Auto−SetE OM-225 311 Page 37...
  • Page 42 228 247-A Figure 7-2. Circuit Diagram For 115 VAC Model OM-225 311 Page 38...
  • Page 43 228 249-A Figure 7-3. Circuit Diagram For 230 VAC Model OM-225 311 Page 39...

  • Page 44: Section 8 − Mig Welding (Gmaw) Guidelines

    SECTION 8 − MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Regulator/ Flowmeter Wire Feeder/...

  • Page 45: Typical Mig Process Control Settings

    8-2. 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. 1/8 or Convert Material .125 in Thickness to...

  • Page 46: Holding And Positioning Welding Gun

    8-3. 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. Hold Gun and Control Gun Trigger Workpiece...

  • Page 47: Conditions That Affect Weld Bead Shape

    8-4. 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. ° Push ° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...

  • Page 48: Gun Movement During Welding

    8-5. 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. Stringer Bead − Steady Movement Along Seam Weave Bead −...

  • Page 49: Troubleshooting − Excessive Spatter

    8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.

  • Page 50: Troubleshooting − Excessive Penetration

    8-10. Troubleshooting − Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Good Penetration S-0639 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase travel speed. Wrong polarity.

  • Page 51: Troubleshooting − Burn-Through

    8-13. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. S-0640 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase and/or maintain steady travel speed. Wrong polarity.

  • Page 52: Common Mig Shielding Gases

    8-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
  • Page 53 Notes...
  • Page 54 Notes...
  • Page 55 Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...
  • Page 56 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 2006 Miller Electric Mfg. Co. 2006−01...

This manual is also suitable for:

Millermatic 140 auto-setM-10Millermatic 180

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