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Miller Electric M-10 Gun, 140, 140 Auto-Set, 180 SECTION 8 MIG WELDING (GMAW) GUIDELINES

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SECTION 8 − MIG WELDING (GMAW) GUIDELINES

8-1. Typical MIG Process Connections

YWeld current can damage

electronic parts in vehicles.

Disconnect both battery

cables before welding on a

vehicle. Pla c e w o r k c l a m p a s

close t o the weld as possible.

Wire Feeder/

Power Source

Workpiece

Gun

Regulator/

Flowmeter

Gas Hose

Shielding Gas

W ork Clamp

light mig 5/967 / Ref. 802 982-A

Contents

Main From Miller to You Page TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage . 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin. WELDING can cause fire or explosion. FLYING METAL can injure eyes. BUILDUP OF GAS can injure or kill. HOT PARTS can cause severe burns. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING STA TIC (ESD) can damage PC boards. 1-5. Principal Safety Standards 1-6. EMF Information SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 2-1. Symboles utiliss . 2-2 . Dangers relatifs au soudage l arc UNE DCHARGE LECTRIQUE peut entraner la mort. LES RAYONS DARC peuvent entra- ner des brlures aux yeux et la peau. LE SOUDAGE peut provoquer un incendie ou une explosion. DES PARTICULES VOLANTES peuvent blesser les yeux. LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou mme la mort. DES PICES CHAUDES peuvent provoquer des brlures graves. e Risque DINCENDIE OU DEXPLO- SION. LA CHUTE DE LAPPAREIL peut blesser. LEMPLOI EXCESSIF peut SUR- CHAUFFER LQUIPEMENT. LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims. 2-5. Principales normes de scurit 2-6. Information EMF SECTION 3 SPECIFICATIONS 3-1. Specifications A. 115 VAC Model * CSA Rating B. 115 VAC Model w/AutoSetE 3-2. Duty Cycle And Overheating A or V A. 115 VAC Model B. 230 VAC Model 3-3. Volt-Ampere Curves SECTION 4 INSTALLATION 4-1. Installing W elding Gun . Correct Incorrect 4-2. Installing W ork Clamp 4-3. Work Cable Routing Inside Unit 4-4. Process/Polarity Table output terminal Connect to positive (+) output put terminal Connect to negative () output GMAW Solid wire with shield- ing gas DCEP Reverse polarity Connect to positive (+) out- 4-6. Installing Gas Supply . 4-7. Selecting A Location And Connecting Input Power For 115 VAC Model 4-8. Selecting A Location And Connecting Input Power For 230 VAC Model 1 4-9. Electrical Service Guide For 230 VAC Model 4-10. Installing Wire Spool And Adjusting Hub Tension Installing 8 in (203 mm) Wire Spool Installing 4 in (102 mm) Wire Spool 4-11. Threading W elding Wire . INPUT POWER Page 4-13. Installing Optional Spool Gun Switch In Welding Power Source . 4-14. Connecting Spool Gun To Millermatic 140/180 Correct Incorrect Gun Fully Seated Gun Not Seated . SECTION 5 OPERATION 5-1. Controls For 115 VAC Model w/Auto-SetE 5-2. Controls For 115 VAC Model 115VWireWelder V V ON OFF 5-3. Controls For 230 VAC Model V V ON OFF 230VWireWelder Page 5-4. Weld Parameter Chart For 115 VAC Model w/AutoSetE Page Page Page 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. . Page 5-7. Weld Parameter Chart For 230 VAC Model w/Factory Set Non-Wire Speed Tracking Mode Page 5-8. Weld Parameter Chart For 230 VAC Model w/Wire Speed Tracking Mode (DCEN) Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded. . Page SECTION 6 MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance 6-2. Overload Protection 6-3. Drive Motor Protection And Tip Saver/Short Circuit Protection 6-4. Changing Drive Roll Or Wire Inlet Guide 6-5. Replacing Gun Contact Tip 6-6. Cleaning Or Replacing Gun Liner 6-7. Replacing Switch And/Or Head Tube 6-8. Troubleshooting Table Page Page Page SECTION 8 MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections 8-2. Typical MIG Process Control Settings 8-3. Holding And Positioning Welding Gun 8-4. Conditions That Affect Weld Bead Shape 8-5. Gun Movement During Welding 8-6. Poor Weld Bead Characteristics 8-7. Good Weld Bead Characteristics 8-8. Troubleshooting Excessive Spatter 8-9. Troubleshooting Porosity 8-10. Troubleshooting Excessive Penetration 8-11. Troubleshooting Lack Of Penetration 8-12. Troubleshooting Incomplete Fusion 8-13. Troubleshooting Burn-Through 8-14. Troubleshooting Waviness Of Bead 8-15. Troubleshooting Distortion 8-16. Common MIG Shielding Gases SECTION 9 PARTS LIST 9-1. Recommended Spare Parts 9-2. Optional Drive Rolls 9-3. Options Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2007 (Equipment with a serial number preface of LH or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Owners Record