Miller Electric Renegade 180 Typical MIG Process Control Settings, Wire Suggested Wire Speed

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12-2. Typical MIG Process Control Settings

.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.





1						1/8 or
						1/8 or
						.125 in

2

3

4

.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.

1Convert Material Thickness to Amperage (A)

(.001 in = 1 ampere)

.125 = 125 A

.Material thickness determines weld parameters.

2 Select Wire Size

Wire Size	Amperage Range
.030 in	40 − 145 A
.035 in	50 − 180 A
.045 in	75 − 250 A

3 Select Wire Speed (Amperage)

125 A based on 1/8 in (3 mm) material thickness. (ipm = inch per minute)

	Wire	Suggested	Wire Speed
	Size	Suggested	(Approx.)
	Size		(Approx.)
	.030 in	2 in per amp	2 x 125 A = 250 ipm
	.035 in	1.6 in per amp	1.6 x 125 A = 200 ipm
	.045 in	1 in per amp	1 x 125 A = 125 ipm

.Wire speed (amperage) controls weld pene- tration (wire speed = burn-off rate).

4 Select Voltage

Low Voltage: wire stubs into work

High Voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage.

.Voltage controls height and width of weld bead.

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OM-228 042 Page 43

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Contents File Engine Drive OM-228 042BProcesses DescriptionFrom Miller to You Table of Contents 10-1 − MaintenanceHOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité − Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsVolt-Ampere Curves Gun SpecificationsDimensions, Weights, And Operating Angles Optional Lifting Eye Weight RatingFuel Consumption Power Source Duty CycleAC Amperes Generator Power CurveGun Duty Cycle And Overheating VoltsAirflow Clearance − InstallationInstalling Welding Generator MovementUse ground device as stated in electrical codes Grounding Generator When Supplying Building SystemsOil Connecting The Battery Electric Start Models OnlyEngine Prestart Checks + −Work Cable Routing Inside Unit Installing Welding GunChanging Weld Polarity Weld Process/Polarity TableThis unit can provide weld out Connecting Single−Phase, 230 Volt AC Utility Input PowerShown with optional cylinder rack Adapter Electrical Service GuideInstalling Wire Spool And Adjusting Hub Tension When a slight force is needed to turn spool, tension is setWeld Position Tools Needed 150 mm 030/.035 Groove Stamped Stamped .030/.035 Tighten Pressure Indicator ScaleThreading The Welding Gun Wood Controls See Section − Operating the Welding GeneratorTo Stop Description Of Controls See SectionTo Start Weld Parameter Chart 20 ga 18 ga 16 ga 14 ga Stainless Steel And 100% CO2 Weld Parameters− Operating Auxiliary Equipment Generator Power Panel ReceptaclesGenerator power decreases as weld current increases Power Source Routine Maintenance − MaintenanceTip Saver/Short Circuit Protection Gun Routine MaintenanceWelding Power Source Overload Protection Drive Motor ProtectionReplacing Gun Contact Tip Changing Drive Roll Or Wire Inlet GuideTurn Off power before replacing contact tip Maintaining Gun Turn off welding power source/wire feederTools Needed 19 mm Replacing Switch And/Or Head TubeStandard Model Shown Stop engine Servicing Air CleanerPrecleaner Paper Element Do not wash paper element or clean with compressed airStop engine. Close fuel valve Adjusting Engine SpeedWelding − TroubleshootingTroubleshooting Generator PowerDoes not run Wire FeederEngine Recommended Spare Parts − Parts ListRecommended Spare Parts OM-217 454 − Electrical DiagramsGun Work Clamp Workpiece Regulator Flowmeter Wire Feeder Power Source Shielding Gas− MIG Welding Gmaw Guidelines Typical MIG Process ConnectionsMaterial thickness determines weld parameters Typical MIG Process Control SettingsThese settings are guidelines only. Material Wire Suggested Wire SpeedGroove Welds Nozzle, and tip of wire is posiHolding And Positioning Welding Gun Tioned correctly on seamFillet Weld Electrode Extension Stickout Conditions That Affect Weld Bead ShapeGun Angles And Weld Bead Profiles Electrode Extensions StickoutGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Incomplete Fusion Troubleshooting − Excessive Penetration12-11 Troubleshooting − Lack Of Penetration Troubleshooting − Distortion 12-13 Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Flat & Horizontal1 Fillet Common MIG Shielding GasesApplication Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment How Much Power Does Equipment Require? Grounding When Supplying Building SystemsFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Cord Lengths for 240 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current Load Watts AmperesSOCKET/WRENCH Selection Table Standard Metric Support ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact