Gebruiksaanwijzing /service van het product OM-230 van de fabrikant Miller Electric
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Processes Description MIG (GMAW ) W elding Flux Cored (FCAW ) W elding Arc Welding Power Source and Wire Feeder OM-230 693C 2007−11 Millermatic 252 R File: MIG (GMA W) V isit our website at www.
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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 8 − MIG WELDING (GMA W) GUIDELINES 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. T ypical MIG Process Connections 36 . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-230 693 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury .
OM-230 693 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
OM-230 693 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
OM-230 693 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Section 25249.
OM-230 693 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007−04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
OM-230 693 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces.
OM-230 693 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué.
OM-230 693 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage.
OM-230 693 Page 9 2-5. P ri nc ipa le s no rm es d e s écu ri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .
OM-230 693 Page 10.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Wire Feed Output X Duty Cycle Do Not Switch While W elding V V .
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 12 4-2. W elding Power Source Duty Cycle And Overheating 4 Minutes W elding 6 Minutes Resting 6 Minutes W elding 4 Minutes Resting Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 13 4-4. Connecting T o Weld Output T erminals 803 778-A ! T urn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat an d start a fire, or damage your ma- chine.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 14 4-6. Connecting Spoolmatic ) 15A Or 30A Gun 804 910-A 1 Gu n Trigger Plug Insert plug into receptacle, and tighten threaded collar . 2 Weld Cable 3 Shielding Gas Hose Route weld cable through opening in front panel.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 15 4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python Ref. 804 910-A / 804 936-A . XR E dge guns p rior to serial n o. LE079101 require an a dapter cor d (par t no.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 16 4-8. Setting Gun Polarity For Wire T ype 1 Polarity Changeover Label Information Always read and follow manufacture’s recommended polarity .
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 17 4-10. Installing Wire Spool And Adjusting Hub T ension When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with 8 in (200 mm) spools.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 18 4-12. Electrical Service Guide Failure to fo llow these electrical service guide recommendations could create an electric shock or fire hazard.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 19 4-13. Selecting A Location And Connecting Input Power 804 912-A L1 L2 230 V AC, 1 18 in (457 mm) of space for airflow ! Do not move or operate unit where it could tip.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 20 4-14. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 21 Notes.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 22 4-15. W eld Parameters.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 23 226 650-B.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 24 SECTION 5 − OPERA TION 5-1. Controls 226 647-B 1 V oltage Control Turn control clockwise to increase voltage. 2 Wire Speed Control Turn control clockwise to increase wire feed speed.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 25 JOG Mode If the trigger on either gun is held for more than 3 seconds without striking an arc, the unit will automatica.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 26 5-2. V oltmeter And Wire Feed Speed Meter Operation 1 V oltmeter 2 Wire Feed Speed Meter Power Up Status Both meters display 888 at unit power up. After 0.5 seconds, preset values appear on both meters.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 27 5-4. Timers 1 V oltage Control 2 Wire Speed Control 3 V oltmeter 4 Wire Feed Speed Meter T o enter the TIMERS menu press and hold the gun trigger while turning on the power switch until the left meter displays (run), then release trigger .
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 28 . W elding wire birdnesting at the welding power source drive rolls may occur if this value is set too high.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 29 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance ! Disconnect power before maintaining.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 30 6-4. Aligning Drive Rolls and Wire Guide ! T urn Off power . V iew is from top of drive rolls looking down with pressure assembly open.
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 31 6-5. T roubleshooting T rouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 4-13 ). Replace building line fuse or reset circuit breaker if open (see Section 4-13 ).
. A complete Parts List is available at www .MillerW elds.com OM-230 693 Page 32 T rouble Remedy No wire feed. Turn Wire Speed control to higher setting (see Section 5-1 ). Clear obstruction in gun contact tip or liner (see welding gun Owner’s Manual).
OM-230 693 Page 33 Notes.
OM-230 693 Page 34 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram.
OM-230 693 Page 35 229 485-A.
OM-230 693 Page 36 SECTION 8 − MIG WELDING (GMA W) GUIDELINES 8-1. T ypical MIG Process Connections ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl a c e w o r k c l a m p a s close t o the weld as possible.
OM-230 693 Page 37 8-2. T ypical MIG Process Control Settings . These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. 1/8 or .
OM-230 693 Page 38 8-3. Holding And Positioning Welding Gun . W elding 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.
OM-230 693 Page 39 8-4. Conditions That Affect Weld Bead Shape . 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.
OM-230 693 Page 40 8-5. Gun Movement During Welding . Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however , for wide groove weld joints or bridging acros s gaps, a weave bead or multiple stringer beads works better .
OM-230 693 Page 41 8-8. T roubleshooting − Excessive Spatter Excessive Spa tter − scattering of molten metal partic les that cool t o solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed.
OM-230 693 Page 42 8-1 1. T roubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick.
OM-230 693 Page 43 8-14. T roubleshooting − W aviness Of Bead W aviness O f Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle.
OM-230 693 Page 44 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.
OM-230 693 Page 45 Problem Remedy Probable Cause W elding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary . W rong size gun liner or contact tip. Match liner and contact tip to wire size and type.
OM-230 693 Page 46 SECTION 9 − P ARTS LIST 9-1. Drive Roll And Wire Guide Kits . Base selection of drive rolls upon the following recommended usages: 1 V -Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007−01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquart.
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