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OM-225 311 Page 45

8-8. Troubleshooting

−

Excessive Spatter

Excessive Spatter

−

scattering of molten metal particles that

cool to solid form near weld bead.

S-0636

Possible Causes

Corrective Actions

Wire feed speed too high.

Select lower wire feed speed.

Voltage too high.

Select lower voltage range.

Electrode extension (stickout) too long.

Use shorter electrode extension (stickout).

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc.

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire.

Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Wrong polarity.

Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 4-5.

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.

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 nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas.

Use welding grade shielding gas; change to different gas.

Dirty welding wire.

Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty.

Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Wrong polarity.

Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

recommended polarity, and see Section 4-5.

Содержание M-10

Страница 1: ... 225 311A 2006 10 Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Flux Cored FCAW Welding Millermatic 140 140 Auto Set And 180 And M 10 Gun File MIG GMAW Visit our website at www MillerWelds com ...

Страница 2: ...tinue 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 most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation...

Страница 3: ...necting Input Power For 115 VAC Model 15 4 8 Selecting A Location And Connecting Input Power For 230 VAC Model 16 4 9 Electrical Service Guide For 230 VAC Model 17 4 10 Installing Wire Spool And Adjusting Hub Tension 17 4 11 Threading Welding Wire 18 SECTION 5 OPERATION 19 5 1 Controls For 115 VAC Model w Auto Sett 19 5 2 Controls For 115 VAC Model 20 5 3 Controls For 230 VAC Model 21 5 4 Weld Par...

Страница 4: ...ing Welding 44 8 6 Poor Weld Bead Characteristics 44 8 7 Good Weld Bead Characteristics 44 8 8 Troubleshooting Excessive Spatter 45 8 9 Troubleshooting Porosity 45 8 10 Troubleshooting Excessive Penetration 46 8 11 Troubleshooting Lack Of Penetration 46 8 12 Troubleshooting Incomplete Fusion 46 8 13 Troubleshooting Burn Through 47 8 14 Troubleshooting Waviness Of Bead 47 8 15 Troubleshooting Disto...

Страница 5: ...10 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach prop...

Страница 6: ...ombustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag D Wear approved safety glasses with side shield...

Страница 7: ...es computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having 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 installation regularly checked and maintaine...

Страница 8: ...A Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The...

Страница 9: ...n selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l opérateur et les normes nationales provinciales et locales D Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cordon d alimentation est bien raccordé à la borne de terre du sectionne...

Страница 10: ...ble de ses poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et prévoir un détecteur d incendie et un ex tincteur à proximité DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à la brosse en fil de fer et le meulage génèrent des étincelles et des particules ...

Страница 11: ...s interférences avec les équipe ments de radio navigation et de communica tion les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l instal lation D L utilisateurest tenu de faire corriger rapidement par un électri cien qualifié les interférences résultant de l installation D Si le FCC sig...

Страница 12: ... Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux le téléphone de la région 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques Le courant de soudage pendant son passage dans le...

Страница 13: ...z Single Phase KVA KW Weight W Gun Overall Dimensions 90 A 18 Volts DC 20 Duty Cycle 63 A 21 Volts DC 20 Duty Cycle 30 140 28 20 15 2 8 2 1 2 4 1 8 60 lb 27 kg Length 17 1 2 in 444 mm Width 10 5 8 in 273 mm Height 15 3 4 in 400 mm Solid Stainless Flux Cored Wire Feed Speed Range Wire Type And Dia 024 030 in 0 6 0 8 mm 023 030 in 0 6 0 8 mm 030 035 in 0 8 0 9 mm 35 420 IPM 0 9 10 7 m min At No Load...

Страница 14: ...ng 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 Duty Cycle Minutes duty1 4 95 230 342 A 230 343 A A 115 VAC Model B 230 VAC Model 3 Minutes Welding 7 Minutes Resting 20 duty cycle at 90 amps 30 duty cycle at 135 amps 60 Hz 2 Minutes Welding 8 Minutes Rest...

Страница 15: ...apabilities of the welding power source Curves of other settings fall between the curves shown 225 265 A 228 250 A A 115 VAC Model B 230 VAC Model 0 5 10 15 20 25 30 0 20 40 60 80 100 120 140 160 A M PE R A G E V O LTA G E M A X M IN 0 5 10 15 20 25 30 0 20 40 60 80 100 120 140 160 180 200 A M PER A G E V O LTAG E M AX M IN ...

Страница 16: ...t gun end is tight against drive assembly 4 3 3 3 2 1 4 2 Installing Work Clamp 1 Nut 2 Work Cable From Unit 3 Work Clamp 4 Screw 5 Work Clamp Tabs Bend tabs around work cable 6 Insulating Sleeves Slide one insulating sleeve over work cable before connecting to clamp Slide insulating sleeves over handles 802 456 A Connection hardware must be tightened with proper tools Do not just hand tighten har...

Страница 17: ... 5 Changing Polarity 1 Lead Connections For Direct Current Electrode Positive DCEP 2 Lead Connections For Direct Current Electrode Negative DCEN Always read and follow wire manufacturer s recommended polarity and see Section 4 4 Close door 1 Ref 203 501 2 C H A N G IN G P O L A R IT Y DCEP Electrode POSITIVE FOR SOLID WIRE DCEN Electrode Negative Flux Core Wire W orkClamp L ead W ire Drive L ead W...

Страница 18: ...face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect supplied gas hose between regulator flowmeter gas hose connection and fitting on rear of welding power source 7 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Check wire manufacturer s recommended flow rate Tools Needed Ref 802 028 802 441 5 8 1 1 8 in 6 1 2 3 Argon Gas Or Mix...

Страница 19: ...vidual branch circuit protected by time delay fuses or circuit breaker is required 3 Plug From Unit Select extension cord of 14 AWG for up to 50 ft 15 m or 12 AWG for 50 up to 200 ft 61 m Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 18 in 460 mm 804 681 A 1 18 in 460 mm 2 3 ...

Страница 20: ...al 7 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 8 Over Current Protection Select type and size of over current protection using Section 4 9 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout de vice ...

Страница 21: ...tor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements Y Caution Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard...

Страница 22: ...ing in the groove Hold wire tightly to keep it from unraveling Ref 802 982 A Ref 205 837 WOOD Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close door Press gun trigger until wire comes out of gun Be sure that tip matches wire diameter Reinstall contact tip and nozzle 2 Turn power on INPUT POWER Tighten 1 2 3 4 Use pressure indicator scale to set a des...

Страница 23: ...7 or 5 8 as applicable 3 Power Switch 4 Over Temperature Light 5 Gun Trigger Receptacle 6 Auto Set Light To use Auto Set mode rotate Wire Speed control inside blue area for the applicable Weld Wire Diameter Auto Set light will turn on and the unit will provide the appropriate wire feed speed for the material thickness selected using the Voltage control see Section 5 4 Rotate Voltage control inside...

Страница 24: ... Section 5 4 5 5 5 6 5 7 or 5 8 as applicable 2 Voltage Control Turn control clockwise to increase voltage see weld parameter chart in welding power source or Section 5 4 5 5 5 6 5 7 or 5 8 as applicable 3 Power Switch 4 Over Temperature Light 5 Gun Trigger Receptacle 225 226 C OVER TEMP TRIGGER V 115V Wire Welder V ON OFF Welds 24 gauge to 3 16 Mild Steel POWER 1 2 3 4 5 ...

Страница 25: ... Section 5 5 5 4 5 6 5 7 or 5 8 as applicable 2 Voltage Control Turn control clockwise to increase voltage see weld parameter chart in welding power source or Section 5 5 5 4 5 6 5 7 or 5 8 as applicable 3 Power Switch 4 Over Temperature Light 5 Gun Trigger Receptacle 225 227 C OVER TEMP TRIGGER V V ON OFF 230V Wire Welder Welds 24 gauge to 5 16 Mild Steel POWER 1 2 3 4 5 ...

Страница 26: ...tings are approximate Adjust as required Means not recommended Thicker materials can be welded using proper technique joint preparation and multiple passes Activate AUTO SETt by selecting the diameter of the welding wire with the WIRE SPEED knob AUTO SETt light comes on Example 030 diameter wire welding 18 ga material Select thickness of the mild steel being welded with the VOLTAGE knob Setup comp...

Страница 27: ... 2 Number on left of slash is Voltage Knob Setting Example 4 65 1 Number on right of slash is Wire Speed Knob Setting Example 4 65 10 90 10 65 10 80 10 60 10 65 10 50 10 50 10 75 5 5 60 5 5 80 7 80 5 5 60 4 5 45 5 55 4 45 3 50 3 40 6 75 6 60 6 5 50 4 5 70 5 5 65 5 5 45 3 40 3 35 4 65 4 45 4 35 5 40 2 5 32 3 40 3 50 2 40 2 32 10 95 7 95 7 70 5 50 4 5 50 4 40 4 5 50 2 35 5 60 ...

Страница 28: ... on left of slash is Voltage Knob Setting Example 4 5 55 2 Number on right of slash is Wire Speed Knob Setting Example 4 5 55 Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded Solid Wire ER70S 6 DCEP Solid Wire ER70S 6 DCEP Flux Core E71T 11 DCEN Stainless Steel DCEP ...

Страница 29: ...60 8 50 10 55 10 95 10 80 5 5 50 3 5 45 6 45 6 55 4 5 55 4 5 70 4 35 6 5 80 6 5 70 NOTE Settings are approximate Adjust as required Means not recommended Thicker materials can be welded using proper technique joint preparation and multiple passes IMPORTANT Match drive roll groove to diameter of wire being used Set Tension knob setting to 3 at start Adjust tension per instructions in the manual 224...

Страница 30: ...hickness of material being welded Solid Wire ER70S 6 DCEP Solid Wire ER70S 6 DCEP Flux Core E71T 11 DCEN Stainless Steel DCEP To enable wire speed tracking proceed as follows 1 Turn Power switch off 2 Rotate Voltage knob to minimum 3 Rotate Wire Speed knob to maximum 4 Hold gun trigger in while turning on Power switch To verify wire speed tracking is on open drive roll pressure arm pull trigger an...

Страница 31: ... proper technique joint preparation and multiple passes IMPORTANT Match drive roll groove to diameter of wire being used Set Tension knob setting to 3 at start Adjust tension per instructions in the manual 232 016 A To disable wire speed tracking proceed as follows 1 Turn Power switch off 2 Rotate Voltage knob to maximum 3 Rotate Wire Speed knob to minimum 4 Hold gun trigger in while turning on Po...

Страница 32: ...e 4 5 55 2 Number on right of slash is Wire Speed Knob Setting Example 4 5 55 045 1 2 mm 000069 035 045 0 9 1 2 mm 194012 035 045 0 9 1 2 mm 194012 030 035 0 8 0 9 mm 194011 024 0 6 mm 194010 035 0 9 mm 000068 030 0 8 mm 000067 024 0 6 mm 087299 DCEP DCEP DCEN DCEP Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded ...

Страница 33: ...95 6 95 6 85 6 65 5 5 45 5 80 5 70 4 5 50 3 5 30 4 5 50 4 5 70 3 15 3 25 3 5 35 4 5 30 4 5 35 5 60 4 40 3 35 4 50 4 45 3 5 25 3 25 4 40 4 25 4 20 2 20 2 15 2 5 10 3 45 2 25 NOTE Settings are approximate Adjust as required Means not recommended Thicker materials can be welded using proper technique joint preparation and multiple passes IMPORTANT Match drive roll groove to diameter of wire being use...

Страница 34: ...0 035 0 9 mm 000068 030 0 8 mm 000067 024 0 6 mm 087299 DCEP DCEP DCEN DCEP Refer to chart below to select Voltage and Wire Speed based on thickness of material being welded To enable wire speed tracking proceed as follows 1 Turn Power switch off 2 Rotate Voltage knob to minimum 3 Rotate Wire Speed knob to maximum 4 Hold gun trigger in while turning on Power switch To verify wire speed tracking is...

Страница 35: ...imate Adjust as required Means not recommended Thicker materials can be welded using proper technique joint preparation and multiple passes IMPORTANT Match drive roll groove to diameter of wire being used Set Tension knob setting to 3 at start Adjust tension per instructions in the manual 045 1 2 mm 202926 024 0 6 mm 220179 030 0 8 mm 220179 202926 035 0 9 mm 220179 202926 To disable wire speed tr...

Страница 36: ...or Protection And Tip Saver Short Circuit Protection A Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative cycle unit power off and back on again B Tip Saver Short Circuit Protection The tip saver short circuit protection extends contact tip life and protects internal components from damage If contact tip is shorted to workpie...

Страница 37: ...ve on the opposite side of the drive roll The groove closest to the motor shaft is the proper groove to thread see Section 4 11 3 Retaining Pin To secure drive roll locate open slot and push drive roll completely over retaining pin then rotate drive roll 1 4 turn to closed slot 2 1 3 802 984 024 Groove 030 035 Groove Stamped 024 Stamped 030 035 6 5 Replacing Gun Contact Tip Ref 802 399 A Y Turn Of...

Страница 38: ...gun cable out straight before installing new liner Head Tube 8 mm Remove liner Remove nozzle contact tip adapter gas diffuser and wire outlet guide Blow out gun casing To Reassemble Gun Install and tighten new liner Cut liner off 3 4 in 20 mm 3 8 in 9 5 mm for aluminum from head tube Install adapter contact tip and nozzle 10 mm ...

Страница 39: ...ghten head tube into cable connector Place head tube in vice and tighten until nuts are tight Remove from vice Reposition handle and install switch housing Secure with handle locking nut Y Turn Off welding power source wire feeder and disconnect gun Remove switch housing Install new switch and connect leads polarity is not important Reas semble in reverse order If replacing head tube continue to e...

Страница 40: ... gun end to feed head adapter and tighten if necessary Low weld output Connect unit to proper input voltage or check for low line voltage Place Power switch in On position see Section 5 2 5 1 or 5 3 Electrode wire feeding stops during welding Straightengun cable and or replace damaged parts welding Adjust drive roll pressure see Section 4 11 Change to proper drive roll groove see Section 6 4 Readj...

Страница 41: ...OM 225 311 Page 37 SECTION 7 ELECTRICAL DIAGRAM 229 578 A Figure 7 1 Circuit Diagram For 115 VAC Model w Auto SetE ...

Страница 42: ...OM 225 311 Page 38 228 247 A Figure 7 2 Circuit Diagram For 115 VAC Model ...

Страница 43: ...OM 225 311 Page 39 228 249 A Figure 7 3 Circuit Diagram For 230 VAC Model ...

Страница 44: ...ons Y Weld current 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 Regulator Flowmeter Gas Hose Shielding Gas Work Clamp light mig 5 967 Ref 802 982 A ...

Страница 45: ...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 ipm 1 6 x 125 A 200 ipm 3 5 x 125 A 437 ipm Set voltage midway between high low voltage Low voltage wire stubs into work High voltage arc is unstable spatter 125 A based on 1 8 in Thickness to Amperage ...

Страница 46: ... 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 Cradle Gun and Rest Hand on Workpiece 2 3 5 4 90 90 0 15 45 45 GROOVE WELDS FILLET WELDS End View Of Work Angle Side View Of Gun Angle End View Of Work Angle Side View Of Gun Angle 1 0 15 S 0421 A ...

Страница 47: ...ectrode 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 EXTENSIONS STICKOUT FILLET WELD ELECTRODE EXTENSIONS STICKOUT Push Perpendicular Drag GUN TRAVEL SPEED Slow Normal Fast S 0634 ...

Страница 48: ...ement 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 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 S 0053 A 8 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or la...

Страница 49: ...ction 4 5 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 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 nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hol...

Страница 50: ...edge 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 Wrong polarity Configure polarity as shown in Section 4 5 Always read and follow wire manufacturer s recommendedpolarity and see Section 4 5 8 12 Troubleshooting Incomplete Fusion Incomplete Fusion fai...

Страница 51: ...allel 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 nozzle Unsteady hand Support 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 ...

Страница 52: ...he 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 Positions Argon 25 CO2 Flat Horizontal1 Fillet All Positions All Positions2 CO2 Flat Horizontal1 Fillet All Positions Tri Mix3 All Positions 1 Globular Transfer 2 Single Pass Welding Only 3 90 HE 7 1 2 AR...

Страница 53: ...Notes ...

Страница 54: ...Notes ...

Страница 55: ...n Heating Coils and Blankets Cables and Non Electronic Controls 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 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushe...

Страница 56: ...d retain with 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 Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering...

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