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TABLE OF CONTENTS

SECTION 8

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MIG WELDING (GMAW) GUIDELINES

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8-1. Typical MIG Process Connections

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8-2. Typical MIG Process Control Settings

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8-3. Holding And Positioning Welding Gun

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8-4. Conditions That Affect Weld Bead Shape

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8-5. Gun Movement During Welding

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8-6. Poor Weld Bead Characteristics

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8-7. Good Weld Bead Characteristics

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8-8. Troubleshooting

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Excessive Spatter

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8-9. Troubleshooting

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Porosity

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8-10. Troubleshooting

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Excessive Penetration

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8-11. Troubleshooting

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Lack Of Penetration

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8-12. Troubleshooting

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Incomplete Fusion

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8-13. Troubleshooting

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Burn-Through

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8-14. Troubleshooting

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Waviness Of Bead

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8-15. Troubleshooting

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Distortion

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8-16. Common MIG Shielding Gases

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8-17. Troubleshooting Guide For Semiautomatic Welding Equipment

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SECTION 9

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PARTS LIST

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WARRANTY

Содержание M-10 GUN

Страница 1: ...rocesses Description Arc Welding Power Source and Wire Feeder OM 1330 220 237A July 2004 Visit our website at www MillerWelds com Millermatic DVI And M 10 Gun R Flux Cored FCAW Welding MIG GMAW Weldin...

Страница 2: ...ue 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 the...

Страница 3: ...rheating 11 4 5 Installing Work Clamp 12 4 6 Installing Welding Gun 12 4 7 Setting Gun Polarity For Wire Type 12 4 8 Installing Gas Supply 13 4 9 Installing MIG Wire Spool and Adjusting Hub Tension 14...

Страница 4: ...ics 36 8 7 Good Weld Bead Characteristics 36 8 8 Troubleshooting Excessive Spatter 37 8 9 Troubleshooting Porosity 37 8 10 Troubleshooting Excessive Penetration 37 8 11 Troubleshooting Lack Of Penetra...

Страница 5: ...hat cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power c...

Страница 6: ...lding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane light...

Страница 7: ...ng a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installati...

Страница 8: ...e 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Su...

Страница 9: ...d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre D Pour ex cuter les branchements d entr e fixer d abord l...

Страница 10: ...ue des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque D Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au but...

Страница 11: ...s et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de causer des interf rences D Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigat...

Страница 12: ...andards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pitts...

Страница 13: ...DC 20 Duty Cycle 30 135 32 15 2 27 1 85 90 A 18 0 Volts DC 20 Duty Cycle 30 135 32 20 2 78 2 23 CSA Rating B 230 VAC Rated Welding Output Amperage Range Maximum Open Cir cuit Voltage DC Amperes Input...

Страница 14: ...nd cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding Y Exceeding duty cycle can damage unit or gun and void warranty Overheating 0 15 A or V OR Reduce...

Страница 15: ...g Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty Do not weld at rated load longer than shown below Using gasless flux cored wire reduces g...

Страница 16: ...drive rolls Tighten knob 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door 803 860 B 1 2 3 4 4 7 Setting Gun Polarity For Wire Type 1 Polarity Changeover Label Info...

Страница 17: ...eter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection For MIG Gun Connect gas hose between regulator flowmetergas hose con nection and f...

Страница 18: ...16 in Use compression spring with 8 in 200 mm spools Tools Needed 072573 B 802 922 Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire spool follow the procedure as shown in the illu...

Страница 19: ...dard Fuse Rating In Amperes 1 Time Delay 2 30 Normal Operating 3 35 Min Input Conductor Size In AWG 12 Max Recommended Input Conductor Length In Feet Meters 79 24 Min Grounding Conductor Size In AWG 1...

Страница 20: ...stomer Supplied 7 Plug NEMA Type 6 50P 8 Receptacle NEMA Type 6 50R Customer Supplied 9 Plug NEMA Type 10 50P Optional 10 Receptacle NEMA Type 10 50R Customer Supplied Select plug for power supply rec...

Страница 21: ...cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trigger until wire comes ou...

Страница 22: ...er valve Secure with hose clamp Slide hose clamp down gas hose from gun Route gas hose through front panel opening and slide hose onto remaining output barbed fitting on diverter valve Secure with hos...

Страница 23: ...equipped with a pre installed barbed fitting cut off fitting from end of hose Connect spool gun gas hose to diverter valve barbed fitting see Section 4 15 2 Gun Trigger Plug Insert plug into receptacl...

Страница 24: ...urn control clockwise to increase voltage 2 Wire Speed Control Set Wire Speed control according to the parameterchart Increase or decrease wire speed to obtain desired bead profile and travel speed 3...

Страница 25: ...OM 1330 Page 21 Notes...

Страница 26: ...OM 1330 Page 22 5 2 Weld Parameter Chart...

Страница 27: ...OM 1330 Page 23 220 493 A...

Страница 28: ...weld terminals 6 Months Blow out or vacuum inside OR Remove drive roll and carrier Apply light coat of oil or grease to drive motor shaft Ref 802 990 6 2 Circuit Breaker CB1 1 Circuit Breaker CB1 If C...

Страница 29: ...nozzle Remove contact tip and install new contact tip Reinstall nozzle Tools Needed 1 2 6 5 Changing Drive Roll and Wire Inlet Guide 1 Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as clos...

Страница 30: ...turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly Ref 800 412 A Correct Incorrect 4 3 2 1 5 Tools Needed 6 7 Removing Knob From Front Panel Y Turn Off...

Страница 31: ...cable out straight before installing new liner Head Tube 1 2 in Remove liner Remove nozzle contact tip adapter gas diffuser and wire outlet guide Blow out gun casing To Reassemble Gun Install and tigh...

Страница 32: ...e with handle locking nut If replacing head tube continue to end of figure 3 Slide handle 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing...

Страница 33: ...proper input voltage or check for low line voltage see Section 4 13 Low high or erratic wire speed Readjust front panel settings see Section 5 1 Change to correct size drive roll see Section 6 5 Readj...

Страница 34: ...OM 1330 Page 30 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Welding Power Source Circuit Diagram...

Страница 35: ...OM 1322 Page 31 220 197 B...

Страница 36: ...urrent can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Wire Feeder Power Source Workpiece Gun Regul...

Страница 37: ...035 in 023 in 40 145 A 50 180 A 30 90 A 035 in Select Wire Speed Select Voltage Wire Recommendation 030 in 035 in 023 in 2 in per ampere 1 6 in per ampere 3 5 in per ampere Wire Speed 2 x 125 A 250 ip...

Страница 38: ...3 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 Cradl...

Страница 39: ...trode 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 EXTENS...

Страница 40: ...nt 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 Sli...

Страница 41: ...sufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozz...

Страница 42: ...Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust pain...

Страница 43: ...pport hand on solid surface or use two hands 8 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of the...

Страница 44: ...ed Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire fe...

Страница 45: ...essary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameters...

Страница 46: ...TION 9 PARTS LIST Hardware is common and not available unless listed 803 864 D 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20 21 22 23 25 26 27 28 29 30 31 24 1 Fig 9 2 2 Fig 9 3 18 Fig 9 4 19 Fig 9 6 Figur...

Страница 47: ...LAMP WORK 300 AMP 1 600318 CABLE WELD COP STRD NO 3 EPDM JKT ORDER BY FT 10FT 196318 COVER CABLE BTRY POST BLK 75 ID 1 21 R2 091685 RESISTOR WW FXD 50 W 25 OHM FASTON TE 1 22 Z1 219549 STABILIZER INCL...

Страница 48: ...OM 1330 Page 44 803 865 C Hardware is common and not available unless listed 18 17 16 15 13 11 10 9 8 7 6 5 4 3 2 1 12 14 19 Figure 9 2 Baffle Center w Components...

Страница 49: ...1 13 PC1 220005 CIRCUIT CARD ASSY 1 PLG1 130203 HOUSING PLUG SKTS SERVICE KIT 1 PLG3 115091 HOUSING PLUG SKTS SERVICE KIT 1 PLG4 131059 HOUSING PLUG PINS SERVICE KIT 1 134201 STAND OFF SUPPORT PC CAR...

Страница 50: ...T 312 18 PUSH ON 63D 07H STL 1 2 148809 BLADE FAN 9 000 5WG 34DEG 312 BORE CCW PLSTC 1 3 188706 MOTOR FAN 230V 50 60HZ 1550 RPM 312 DIA SHAFT 1 4 203711 WINDTUNNEL 9 000 1 5 216396 VALVE 24VAC 2WAY CU...

Страница 51: ...WITCH SELECTOR 6 POSITION 1 136343 SCREW K50X 20 PAN HD PHL STL PLD PT THREAD FORMING 4 7 C2 3 136735 CAPACITOR CER DISC 1UF 500VDC STRIP 2 8 048282 RECEPTACLE W SOCKETS 2 9 129524 TERM FRICT 250X032...

Страница 52: ...EXT 394 SHAFT X 1 16 079633 FITTING HOSE BRS BARBED M 3 16TBG 1 17 601966 SCREW 375 16 X 1 25HEXHD 2 18 604538 WASHER FLAT STL SAE 312 1 19 204585 KNOB 1 20 173619 CARRIER DRIVE ROLL W COMPONENTS 1 21...

Страница 53: ...ING retaining 1 5 169 718 TUBE head 1 6 169 738 NUT locking handle 1 7 169 719 NUT jam 1 8 180 433 CORD trigger assembly 1 9 209 495 CONNECTOR feeder 1 10 079 974 O RING 500 ID x 103CS rbr 2 11 194 01...

Страница 54: ...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 4 V Knurled rolls for har...

Страница 55: ...nd Blankets APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Co...

Страница 56: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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