Related Manuals for Miller Electric Millermatic Passport Plus
Summary of Contents for Miller Electric Millermatic Passport Plus
- Page 1 OM-235 825E 2010−10 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic Passport Plus File: MIG (GMAW) Visit our website at www.MillerWelds.com...
- Page 2 ISO 9001 Quality System Standard. particular model are also provided. 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 or individual specification sheets.
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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 _2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. - Page 6 D Keep your head out of the fumes. Do not breathe the fumes. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
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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 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 For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques. - Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser. -
Page 12: Proposition Californienne 65 Avertissements
Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité... -
Page 13: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,... - Page 14 OM-235 825 Page 10...
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Page 15: Section 3 − Specifications
SECTION 3 − SPECIFICATIONS 3-1. Specifications Amperes Input at Rated Maximum Input Weight Overall Rated Load Out- Welding Amperage Range Open-Circuit Voltage put, 50/60 Hz, W/ Gun Dimensions Output Voltage DC Single-Phase 110 A @ 19.5 Volts DC, 20% Duty Cycle 23.1 2.69 2.66... -
Page 16: Duty Cycle And Overheating
3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. 115 VAC DUTY CYCLE If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. -
Page 17: Section 4 − Installation
SECTION 4 − INSTALLATION 4-1. Installing Work Clamp Tighten connection hardware with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and ex- cessive heating of the work clamp. Work Clamp Work Cable From Unit Screw Flat Washer Lock Washer... -
Page 18: Process/Polarity Table
4-3. Process/Polarity Table Cable Connections Process 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 − Self-shielding wire − DCEN −... -
Page 19: External Shielding Gas Supply
4-6. External Shielding Gas Supply Shielding Gas Connector The shielding gas connector allows connecting an external shielding gas supply to the unit. Internal/External Transfer Switch The Internal/External Transfer switch allows changing between the internal or external shielding gas supply. Place switch in the External Gas Supply position. -
Page 20: 115 Vac Input Power Requirements
4-7. 115 VAC Input Power Requirements Connect input power cord to a 20 A individual branch circuit. If connecting to a circuit protected by fuses, use a time-delay fuse marked “D”. 4-8. Connecting 1-Phase Input Power For 230 VAC Installation must meet National and Local Codes −... -
Page 21: Electrical Service Guide For 230 Vac
4-9. Electrical Service Guide For 230 VAC Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. Actual input voltage should not exceed 10% of indicated required input voltage. -
Page 22: Serial Number And Rating Label Location
4-11. Serial Number And Rating Label Location The serial number and rating information for this product is located on top. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-12. -
Page 23: Selecting A Location And Connecting Input Power
4-13. Selecting A Location And Connecting Input Power Do Not cut off power cord connector and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product warranty. Do not move or operate unit where it could tip. -
Page 24: Installing 4 In. (102 Mm) Wire Spool And Adjusting Hub Tension
4-14. Installing 4 in. (102 mm) Wire Spool And Adjusting Hub Tension Removing 8 in. (203 mm) Spool Components Hub Nut Brake Adjust Knob Spring Nylon Washer Spool Hub Brake Washer Remove brake adjust knob and spring, and nylon washer. Remove and retain hub nut, spool hub, and brake washer. -
Page 25: Installing And Threading Welding Wire
4-15. Installing And Threading Welding Wire Installing Wire And Adjusting Hub Tension: Retaining Nut Hub Tension Adjustment Hold wire tightly to keep Screw it from unraveling. Remove retaining ring, and install spool so hub pin fits spool hole. Re- install retaining nut. Adjust tension screw so only a slight force is needed to turn spool. -
Page 26: Section 5 − Operation
(Spool Gun) Pressing switch will change inductance to fit material type and Stainless Steel operator’s preference. Mild Steel Power Switch MADE IN MILLER ELECTRIC MFG. CO., APPLETON, WI. USA Rear View Ref. 235 125-B / Ref. 803 809-D OM-235 825 Page 22... -
Page 27: Weld Parameter Chart
5-2. Weld Parameter Chart 235 557-C OM-235 825 Page 23... -
Page 28: Section 6 − Maintenance &Troubleshooting
SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance 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 Damaged Or Unreadable... -
Page 29: Changing Drive Roll Or Wire Inlet Guide
6-3. 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: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram OM-235 825 Page 26... - Page 31 235 780-A OM-235 825 Page 27...
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Page 32: 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. This unit can operate for either the internal or Disconnect both battery an external shielding gas supply. cables before welding on a vehicle. -
Page 33: 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. Low voltage: wire stubs into work Select voltage and wire feed High voltage: arc is unstable (spatter) speed from parameter chart... -
Page 34: 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 35: 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 36: 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 37: 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 38: 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 39: 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 40: 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 41: Section 9 − Parts List
SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Item Part Description Quantity ..... 246 372 NOZZLE, slip type .500 orf flush . - Page 42 Notes...
- Page 43 LIMITED WARRANTY − Subject to the terms and conditions 90 Days — Parts Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its Accessory (Kits) 1-800-4-A-MILLER original retail purchaser that new Miller equipment sold after the...
- Page 44 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 2010 Miller Electric Mfg. Co. 2010−01...
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