Related Manuals for Miller MILLERMATIC 135
Summary of Contents for Miller MILLERMATIC 135
- Page 1 OM-1324 204 408E January 2004 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic 135/175 And M-10 Gun 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.
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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.
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 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.
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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: 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 American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org). -
Page 9: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- Y Identifie un message de sécurité... - Page 10 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.
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Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à... -
Page 12: Principales Normes De Sécurité
2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.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 Open-Circuit Amperage Range 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% 2.88... -
Page 14: Duty Cycle And Overheating
3-2. 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) A. 115 VAC opens, output stops, and cooling Model fan runs. Wait fifteen minutes for RatedOutput 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. Voltage Control @ 0 Voltage Control @ 1 Voltage Control @ 2 Voltage Control @ 3 Voltage Control @ 4... -
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: Process/Polarity Table
4-4. Process/Polarity Table Cable Connections Process Process Polarity Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output ing gas put terminal terminal FCAW −... -
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-de- 18 in lay fuses or circuit breaker is re- (460 mm) quired. 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 Rating Label Supply correct input power. Plug (NEMA 6-50P) Receptacle (NEMA 6-50R) Connect plug to receptacle. Line Disconnect Device 18 in (457 mm) of See Section 4-9. space for airflow Y Special installation may be required where gasoline or volatile liquids are present −... -
Page 21: Electrical Service Guide For 230 Vac Model
4-9. Electrical Service Guide For 230 VAC Model 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) 66 (20) Min Grounding Conductor Size In AWG Reference: 1996 National Electrical Code (NEC) S-0092-J... -
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 Wire Speed Control Voltage Control Power Switch Turn control clockwise to increase wire Turn control clockwise to increase voltage Over Temperature Light feed speed. (see weld parameter chart in (see weld parameter chart in welding welding power source or Sections 5-2 and power source or Sections 5-2 and 5-3, as 5-3, as applicable). -
Page 24: Weld Parameter Chart For 115 Vac Model
5-2. Weld Parameter Chart For 115 VAC Model Selecting Wire, Gas and Control Settings Note: 1. Settings are approximate. Adjust as required. Means not recommended. ”−−” 3. Thicker materials can be welded using proper technique, joint preparation and multiple passes. Suggested Suggested Material... - Page 25 Metal Select Voltage Wire Speed Being Welded Based on Thickness Number on left of slash Number on right of slash is Voltage Knob Setting. is Wire Speed Knob Setting. 3/16” 1/8” (4.8 (3.2 (1.6 (0.9 (0.8 10 / 75 4.5 / 60 3 / 45 2 / 40 −−−...
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Page 26: Weld Parameter Chart For 230 Vac Model
5-3. Weld Parameter Chart For 230 VAC Model Selecting Wire, Gas and Control Settings Note: 1. Settings are approximate. Adjust as required. Means not recommended. ”−−” 3. Thicker materials can be welded using proper technique, joint preparation and multiple passes. Suggested Suggested Material... - Page 27 Wire Metal Select Voltage Speed Based on Thickness Being Welded Number on left of slash Number on right of slash is Voltage Knob Setting. is Wire Speed Knob Setting. 1/4” 3/16” 1/8” (6.4 (4.8 (3.2 (1.6 (0.9 (0.8 10 / 100 6 / 100 4.5 / 85 3.5 / 70...
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Page 28: Section 6 − Maintenance &Troubleshooting
SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Repair or Clean unreadable replace tighten weld labels. cracked terminals. weld cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. 6-2. -
Page 29: 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 30: 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 31: 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 32: Troubleshooting Table
6-8. Troubleshooting Table Trouble Remedy No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 4-7). does not run. does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 5-1). Reset welding power source circuit breaker if open. -
Page 33: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM 203 765 Figure 7-1. Circuit Diagram For 115 VAC Model OM-1324 Page 29 Return To Table Of Contents... - Page 34 203 794 Figure 7-2. Circuit Diagram For 230 VAC Model OM-1324 Page 30 Return To Table Of Contents...
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Page 35: 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 36: 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 37: 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 38: 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 39: 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 40: 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 41: 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 42: 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 43: 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 44: Section 9 − Parts List
SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 803 614-A Figure 9-1. Main Assembly OM-1324 Page 40 Return To Table Of Contents... - Page 45 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ....202 581 BASE, lower ........... .
- Page 46 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly (Continued) ....208 267 LABEL, weld guide (115 VAC model) .......
- Page 47 203 565 Figure 9-2. Wire Feed Drive Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-2. Wire Feed Drive Assembly ....202 500 HOUSING, plastic drive motor .
- Page 48 802 388-A Figure 9-3. M-10 Gun OM-1324 Page 44 Return To Table Of Contents...
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Page 49: Parts List
Item Part Description Quantity Figure 9-3. M-10 Gun ....169 715 NOZZLE, slip type .500 orf flush ....... . . ♦087 299 . - Page 50 Notes...
- Page 51 Effective January 1, 2003 (Equipment with a serial number preface of “LC” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets below, Miller Electric Mfg.
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Page 52: Options And Accessories
Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...
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