Miller Electric Millermatic Passport Plus Owner'S Manual Download Page 1

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OM-235 825E

2010

−

Processes

Description

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Arc Welding Power Source And Wire

Feeder

Millermatic Passport Plus

File: MIG (GMAW)

Visit our website at

www.MillerWelds.com

Summary of Contents for Millermatic Passport Plus

Page 1: ...35 825E 2010 10 Processes Description MIG GMAW Welding Flux Cored FCAW Welding Arc Welding Power Source And Wire Feeder Millermatic Passport Plus R File MIG GMAW Visit our website at www MillerWelds c...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...Cycle And Overheating 12 SECTION 4 INSTALLATION 13 4 1 Installing Work Clamp 13 4 2 Connecting Welding Gun 13 4 3 Process Polarity Table 14 4 4 Changing Polarity 14 4 5 Internal Shielding Gas Supply...

Page 4: ...32 8 6 Poor Weld Bead Characteristics 32 8 7 Good Weld Bead Characteristics 32 8 8 Troubleshooting Excessive Spatter 33 8 9 Troubleshooting Porosity 33 8 10 Troubleshooting Excessive Penetration 34 8...

Page 5: ...r when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage...

Page 6: ...Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent weld...

Page 7: ...panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels cover...

Page 8: ...web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website ww...

Page 9: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivante...

Page 10: ...u laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer...

Page 11: ...lt rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz com...

Page 12: ...stan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences D L nergie lectromagn tique risque de provoquer d...

Page 13: ...r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Ap...

Page 14: ...OM 235 825 Page 10...

Page 15: ...Flux Cored Wire Feed Speed Range 023 035 in 0 6 0 8 mm 030 035 in 0 8 0 9 mm 40 400 IPM 1 0 10 0 m min 230 VAC 150 A 21 5 Volts DC 20 Duty Cycle 130 A 20 5 Volts DC 60 Duty Cycle 30 180 45 17 7 4 06 3...

Page 16: ...ooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit or gun and void warranty Overheating 0 15 A or V OR Reduc...

Page 17: ...g Welding Gun Ref 803 810 E Ref 802 517 A 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob insert gun end into block Po sition outlet wire guide as close as possible to drive rolls...

Page 18: ...ose door Ref 220 579 A Ref 803 811 1 2 4 5 Internal Shielding Gas Supply 1 Internal Shielding Gas Bottle The internal shielding gas bottle is for CO2 gas only 2 Regulator 3 Internal External Transfer...

Page 19: ...to the unit 2 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 posi...

Page 20: ...terminal 1 Black And White Input Conductor L1 And L2 2 Green Or Green Yellow Grounding Conductor 3 Input Power Cord 4 Disconnect Device switch shown in the OFF position 5 Disconnect Device Grounding...

Page 21: ...Length In Feet Meters 65 20 Min Grounding Conductor Size In AWG 4 14 Reference 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circu...

Page 22: ...4 Plug NEMA Type 5 20P Optional 5 Receptacle NEMA Type 5 20R Customer Supplied 6 Plug NEMA Type 6 50P 7 Receptacle NEMA Type 6 50R Customer Supplied Follow electrical service guide for 230 VAC in Sec...

Page 23: ...NEMA Type 5 15P 3 Receptacle NEMA Type 5 15R Customer Supplied 4 Plug NEMA Type 5 20P Optional 5 Receptacle NEMA Type 5 20R Customer Supplied 6 Plug NEMA Type 6 50P 7 Receptacle NEMA Type 6 50R Custo...

Page 24: ...6 1 Hub Nut 2 Brake Adjust Knob 3 Spring 4 Nylon Washer 5 Spool Hub 6 Brake Washer Remove brake adjust knob and spring and nylon washer Remove and retain hub nut spool hub and brake washer 2 3 4 4 1 B...

Page 25: ...t Open pressure assembly hold wire tightly and cut off end Push wire through guides into gun Close and tighten pressure assem bly Press gun trigger until wire comes out gun Feed wire against wooden su...

Page 26: ...Mild Steel Indicator Light 6 Stainless Steel Indicator Light 7 Aluminum Spool Gun Indicator Light Indicator light works with Spoolmate 100 Series spool gun Switch supplied with spool gun is NOT used...

Page 27: ...OM 235 825 Page 23 5 2 Weld Parameter Chart 235 557 C...

Page 28: ...place To be done by Factory Authorized Service Agent Reference Every 3 Months l Damaged Or Unreadable Labels l Repair Or Replace Cracked Weld Cable Clean And Tighten Weld Terminals Every 6 Months OR I...

Page 29: ...ll consists of two differ ent sized grooves The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll The groove closest to the motor shaft...

Page 30: ...OM 235 825 Page 26 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram...

Page 31: ...OM 235 825 Page 27 235 780 A...

Page 32: ...nect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Workpiece Gun Regulator Flowmeter Gas Hose External Shielding Gas Supply Work Clamp light mig 5 9...

Page 33: ...st welds to be sure they comply to specifications NOTE Ref 803 809 D Voltage controls height and width of weld bead Wire speed amperage controls weld penetration wire speed burn off rate Set voltage m...

Page 34: ...13 mm past end of nozzle and tip of wire is positioned correctly on seam NOTE 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Crad...

Page 35: ...ctrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage NOTE Short Normal Long Short Normal Long 10 10 GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTEN...

Page 36: ...ment Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 8 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 S...

Page 37: ...tion 4 3 8 9 Troubleshooting Porosity Porosity small cavities or holes resulting from gas pockets in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Incr...

Page 38: ...dge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed Wr...

Page 39: ...llel and does not cover joint formed by base metal S 0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond n...

Page 40: ...e most commonly used shielding gases are listed in the following table Application Gas Spray Arc Steel Short Circuiting Steel Short Circuiting Stainless Steel Short Circuiting Aluminum Argon All Posit...

Page 41: ...isting of 1 194 012 LINER monocoil 035 045 wire x 15ft consisting of 1 079 975 O RING 187 ID x 103CS rbr 1 OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer...

Page 42: ...Notes...

Page 43: ...bles No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Cont...

Page 44: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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