What should I do if the wire feed stops during welding?

Several causes are possible: straighten the gun cable and/or replace damaged components, adjust drive roll pressure, replace the drive roll with the correct groove size, and readjust hub tension. Also check that the wire is seated in the correct drive roll groove, replace the contact tip if blocked, and clean or replace the inlet wire guide or liner if clogged. If the issue persists, release the gun trigger to reset the torch and motor protection circuit. (Page 30)

How do I perform routine maintenance on the Millermatic 211?

Every 3 months, inspect labels for legibility and check welding terminals and welding cables. Every 6 months, blow out or clean the interior of the unit. Always stop the engine/power before performing any maintenance. In heavy service conditions, perform maintenance more frequently. (Page 26)

What should I do if the machine overheats and stops outputting current?

If the unit overheats, the thermostat (TP1) opens, output stops, and the fan continues running — allow the fan to run with the torch trigger released until the unit cools and the thermostat resets. The overheat indicator light will flash when this occurs. Reduce amperage or duty cycle before resuming welding. (Pages 8 and 26)

How do I use the Auto-Set feature to weld mild steel?

To use Auto-Set, turn the Wire Speed control into the blue or green zone corresponding to your wire diameter — the Auto-Set indicator light will illuminate. Then turn the Voltage control to the blue/green zone matching the material thickness you are welding, and the machine automatically sets the appropriate voltage and wire feed speed. Blue zones are for 0.035" wire and green zones are for 0.030" wire. (Page 21 and 24)

What is the correct polarity for MIG welding with solid wire versus flux-cored wire?

For MIG/MAG welding with solid wire and shielding gas, use DCEP (electrode positive/reverse polarity), connecting the torch cable to the positive (+) output terminal. For flux-cored wire (FCAW) without shielding gas, use DCEN (electrode negative/straight polarity), connecting the torch cable to the negative (−) output terminal. Always follow the wire manufacturer's recommended polarity. (Page 11)

What is the recommended shielding gas flow rate for MIG welding?

The typical flow rate is 9.4 L/min or 157 cc/s (20 ft³/h). You should verify the flow rate recommended by the wire manufacturer, as it may differ. The flow rate should be set while gas is flowing through the welding power source and out through the gun. (Page 12)

What causes excessive spatter during MIG welding and how do I fix it?

Excessive spatter can be caused by wire feed speed that is too high, voltage that is too high, electrode extension that is too long, dirty workpiece, insufficient shielding gas at the arc, dirty welding wire, or incorrect polarity. Corrective actions include reducing wire speed or voltage, shortening electrode extension, cleaning the base metal of grease/oil/rust/paint, increasing shielding gas flow, using clean dry wire, and verifying correct polarity per Section 3-5. (Page 39)

What are the duty cycle ratings for the Millermatic 211 Auto Set?

The 120VAC model is rated at 90A at 20 Volts DC with a 20% duty cycle, meaning it can weld for 2 minutes then requires an 8-minute rest. The 230VAC model is rated at 150A at 23.5 Volts DC with a 30% duty cycle at 60Hz, allowing 3 minutes of welding followed by a 7-minute pause. Exceeding the duty cycle can damage the unit and void the warranty. (Page 8)

What should I do if the machine overheats during welding?

If the unit overheats, the thermostat(s) will trip, output will stop, and the fan will run. Wait fifteen minutes to allow the unit to cool down before resuming welding. Reduce amperage or duty cycle before welding again to prevent recurrence. (Page 8)

How do I use the Auto-Set feature on the Millermatic 211?

To use Auto-Set, turn the wire speed control into the blue/green zone that corresponds to your wire diameter — the Auto-Set indicator light will illuminate. Then turn the voltage control to the blue/green zone matching the material thickness you are welding, and the machine will automatically set the appropriate voltage and wire feed speed. Blue zones are for 0.035-inch wire and green zones are for 0.030-inch wire. (Page 21)

What causes excessive spatter and how can I fix it?

Excessive spatter can be caused by wire feed speed that is too high, voltage that is too high, electrode extension that is too long, a dirty workpiece, insufficient shielding gas, dirty welding wire, or incorrect polarity. Corrective actions include reducing wire feed speed and voltage, cleaning the base metal of grease, oil, rust, and paint, increasing shielding gas flow, and verifying polarity per Section 3-5. (Page 39)

How do I replace the contact tip on the M-10 gun?

Turn off the power source before replacing the contact tip. Cut the welding wire at the contact tip, remove the nozzle, then unscrew and remove the old contact tip. Install a new contact tip and reattach the nozzle. Make sure the contact tip matches the wire diameter being used. (Page 27)

What routine maintenance should I perform on the Millermatic 211?

Every 3 months, check that labels are legible and inspect the welding terminals and welding cables. Every 6 months or as needed, blow out the interior of the unit. Always stop the motor/turn off the unit before performing any maintenance. For intensive service conditions, perform maintenance more frequently. (Page 26)

How do I thread the welding wire into the Millermatic 211?

First, lay the torch cable in a straight line. Open the pressure device and cut the wire end. Push the wire through the guides in the torch while keeping tension on it. Use the pressure scale starting at setting 3, then adjust as needed. Ensure the wire is properly seated in the correct groove of the drive roller. After advancing the wire to check pressure, cut the wire and close the pressure device.

What should I do if the welder overheats and shuts down?

If the overheating thermostat opens, the output will stop and the fan will run. Allow the equipment to cool for 15 minutes before resuming operation. After cooling, reduce either the amperage or the duty cycle (reduce welding time/increase rest periods) before continuing to weld.

What is the recommended gas flow rate for MIG welding?

The typical gas flow rate is 9.4 L/min or 157 cc/s (20 cubic feet per hour). However, you should verify the recommended flow rate from the wire manufacturer's specifications. The flow should be adjusted while gas is flowing through the power source and out through the torch.

What protection does the welder have against short circuits?

The contact tip short-circuit protection prevents damage by cutting the welding output if the contact tip shorts to the workpiece. The fan continues to run. To resume operation, release the torch trigger to reset the circuit. If the contact tip is stuck to the workpiece, release the trigger, stop the unit, and manually separate the tip before restarting.

What should I check if the welding wire stops advancing during welding?

Check the following in order: straighten the torch cable, adjust the drive roller pressure, verify you have the correct drive roller groove size, check the hub tension, ensure the wire is in the correct groove, replace the contact tip if blocked, clean or replace the input guide or liner if clogged, replace broken or worn pressure roller bearings, check torch trigger connections, remove any obstructions in the drive assembly and liner, and release the trigger to reset protection circuits.

How do I replace the torch contact tip?

First, turn off the power. Cut the welding wire at the contact tip and remove the nozzle. Unscrew and remove the old contact tip, then install a new one. Reinstall the nozzle. Use appropriate tools for this maintenance task.

What is the Auto-Set feature and how do I use it?

Auto-Set provides simple one-knob setup for mild steel welding. To use it, turn the wire speed knob to the colored zone (blue for 0.035" wire, green for 0.030" wire) matching your wire diameter—the Auto-Set light will illuminate. Then turn the voltage knob to the colored zone matching your material thickness. The machine automatically provides the correct wire speed and voltage for that combination.

How do I properly set up the spool tension?

Install the spool support and adjust the hub tension until a light effort is required to turn the spool by hand. This ensures proper tension on the wire spool. The tension adjustment varies depending on whether you are using a 102 mm or 203 mm spool.

What is the duty cycle of the Millermatic 211 Auto Set on 120V vs 230V power?

On 120VAC, the duty cycle is 20% at 90A, meaning you can weld for 2 minutes then must pause for 8 minutes. On 230VAC at 60Hz, the duty cycle is 30% at 150A, allowing 3 minutes of welding followed by a 7-minute pause. Exceeding the duty cycle can damage the unit and void the warranty. (Page 8)

What is the maximum extension cord length I can use with the Millermatic 211?

For 120V operation, the maximum recommended extension cord length is 8 meters (27 feet) using 2.5 mm² (14 AWG) conductor. For 230V operation, the maximum length is 16 meters (53 feet) using the same 2.5 mm² (14 AWG) conductor. When calculating maximum length, remember to include the length of conductor between the disconnect switch and the wall outlet. (Page 14)

What happens when the contact tip short-circuits to the workpiece, and how do I reset the machine?

If the contact tip short-circuits against the workpiece, the machine cuts welding output but the fan continues to run. To resume operation, release the torch trigger to reset the unit. If the contact tip is stuck to the workpiece, release the trigger, turn off the machine, and free the contact tip from the workpiece, then inspect and replace it if damaged before restarting. (Page 26)

How do I change the polarity on the Millermatic 211?

To change polarity, you must disconnect the wire drive lead and work clamp leads from their current terminals and reconnect them to the opposite terminals. Use DCEP (Direct Current Electrode Positive) for solid wire, and DCEN (Direct Current Electrode Negative) for flux-cored wire. Always use tools to tighten the connections properly, not by hand.

Miller Millermatic 211 Auto Set — Manual, FAQ & Troubleshooting

Name: Miller Millermatic 211 Auto Set
Brand: Miller

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|Visit our website at www.MillerWelds.com

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OM-234 016D 2007−11

Processes

MIG (GMAW) Welding

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Description

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Wire Feeder Spool Gun

Spoolmate 100 Series

############ File: Wire Feeder

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From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue 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 quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

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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. The possible hazards are shown in the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

NOTICE − Indicates statements not related to personal injury.

Indicates special instructions.

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This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

######### 1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

############ ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit.

Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

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Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

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.

When making input connections, attach proper grounding conductor first − double-check connections.

Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.

Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.

Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal.

############ SIGNIFICANT DC VOLTAGE exists in inverter-type welding power sources after removal of input power.

Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

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############ HOT PARTS can cause severe burns.

Do not touch hot parts bare handed. Allow cooling period before working on gun or torch.

To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

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############### FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator.

Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

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Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

############ ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under your helmet.

Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.

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############## WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

Do not weld where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards).

Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).

Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards.

Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or bypass them. 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 or DIRT can injure eyes.

Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

Wear approved safety glasses with side shields even under your welding helmet.

############ BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator.

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################### MAGNETIC FIELDS can affect Implanted Medical Devices.

Wearers of Pacemakers and other Implanted Medical Devices should keep away.

Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

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############ NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

Wear approved ear protection if noise level is high.

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############ CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder − explosion will result.

Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.

Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

######### 1-3. Additional Symbols For Installation, Operation, And Maintenance

############ FIRE OR EXPLOSION hazard.

Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables.

Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

############ FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit.

If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

############ OVERUSE can cause OVERHEATING

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Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto 416-747-4044, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036–8002 (phone: 212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (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 Effects Of Low Frequency Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them, or using a cable cover.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from operator as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

#################### About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

###### SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

fre_som_2007−04

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Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

######### 2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures personnelles.

Indique des instructions spécifiques.

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Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger.

######### 2-2. Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.

############ UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort.

Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la

sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger.

Ne pas toucher aux pièces électriques sous tension. Porter des gants isolants et des vêtements de protection secs et sans trous.

S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol.

Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.

Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.

Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.

D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante

(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !

Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

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.

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 sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.

Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes.

Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu peut entraîner la mort.

L’équipement doit être hors tension lorsqu’il n’est pas utilisé. Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés. Ne pas enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine.

Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée.

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N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. S’assurer que tous les panneaux et couvercles sont correctement en place.

Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.

Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage.

############ Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation.

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.

############ DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

Ne pas toucher à mains nues les parties chaudes. Prévoir une période de refroidissement avant de travailler à l’équipement.

Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.

| | |---|

############ LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

Eloigner votre tête des fumées. Ne pas respirer les fumées.

À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.

Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

| | |---|

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############ LES RAYONS DE L’ARC peuvent pro voquer des brûlures dans les yeux e sur la peau.

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.

Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.

Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

| | |---|

############ LE SOUDAGE peut provoquer un in cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tel que des réservoirs, tambours ou des conduites peu provoquer leur éclatement. Des étincelles peuven

être projetées de l’arc de soudure. La projection d’étincelles, des pièce chaudes et des équipements chauds peut provoquer des incendies e des brûlures. Le contact accidentel de l’électrode avec des objet métalliques peut provoquer des étincelles, une explosion, un surchauf fement ou un incendie. Avant de commencer le soudage, vérifier e s’assurer que l’endroit ne présente pas de danger.

Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.

Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud.

Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.

Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.

Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).

Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.

Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.

Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

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LES BOUTEILLES peuvent exploser si elles sont endommagées.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de sou-

dage, les manipuler avec précaution.

Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.

Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.

Ne jamais placer une torche de soudage sur une bouteille à gaz. Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. Ne jamais souder une bouteille pressurisée − risque d’explosion. Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état. Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille. Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.

Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité.

######### 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

############ Risque D’INCENDIE OU D’EXPLOSION.

Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. Ne pas installer l’appareil à proximité de produits inflammables.

Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.

############ LA CHUTE DE L’APPAREIL peut blesser.

Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.

Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.

En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

############ L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

Prévoir une période de refroidissement ; respecter le cycle opératoire nominal. Réduire le courant ou le facteur de marche avant de poursuivre le soudage.

Ne pas obstruer les passages d’air du poste.

############ LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.

Porter un écran facial pour protéger le visage et les yeux.

Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

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############ LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences.

Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.

Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.

Si le FCC signale des interférences, arrêter immédiatement l’appareil.

############ LE SOUDAGE À L’ARC risque de provoquer des interférences.

L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.

Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.

En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

|2-4. Proposition californienne 65 Avertissements| |---|

Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants)

Les batteries, les bornes et autres accessoires contiennent du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation.

Pour les moteurs à essence :

Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation.

Pour les moteurs diesel :

Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations congénitales ou autres problèmes de procréation.

|2-5. Principales normes de sécurité| |---|

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone :

1-877-413-5184, site Internet : www.global.ihs.com).

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National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet : www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de Canadian Standards Association, 5060 Mississauga, Ontario, Canada

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site Internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 11 West 43rd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (téléphone : 1-866-512-1800) (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 les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ». Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.

Pour réduire les champs magnétiques sur le poste de travail, appliquer les procédures suivantes :

1. Garder les câbles ensemble, les torsader, les scotcher, ou les recouvrir d’une housse.

2. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber pas et ne pas entourer pas les câbles autour de votre corps.

4. Garder le poste de soudage et les câbles le plus loin possible de vous.

5. Connecter la pince sur la pièce aussi près que possible de la soudure.

################### En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.

| | |---|

#### SECTION 3 − INSTALLATION

3-1. Specifications

|Wire Diameter Range|Approximate Wire Feed Range|Cooling Method|Maximum Spool Size|Weld Circuit Rating|Overall Dimensions|Weight| |---|---|---|---|---|---|---| |.030 Thru .035 in (0.8 Thru 0.9 mm) Aluminum Wire Or Flux Cored Wire

.023 Thru 035 in (0.6 Thru 0.9 mm) Solid Wire|Millermatic 140 AutoSet: 5 To 365 ipm (0.13 To 9.27 mpm) Millermatic 140: 5 To 435 ipm

(0.13 To 11.05 mpm) Millermatic 180 And

Renegade 180: 65 To 625 ipm

(1.65 To 15.88 mpm)
|Air Cooled|4 in (102 mm) Diameter|22.5 Volts, 135 Amperes, 30% Duty Cycle Using Argon Shielding Gas|Length: 13 in (330 mm) Width: 2-1/4 in (57 mm)

Height: 8 in (203 mm)|5.6 lb (2.54 kg) Gun With Cable|

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7 Polarity Changeover Terminal Block

To make proper polarity connection, see welding power source Owner’s Manual. Typically, DCEP is used for solid and aluminum wire.

Close door.

804 755-B

######### 3-6. Installing Wire Spool And Threading Welding Wire

| | |![image 11](o234016d_mil_images/imageFile11.png)| | | |1 Thumb Screw
2 Spool Cover Remove thumb screw and spool
| |---|---|---|---|---|---|---| |804 985-A

Tools Needed: cover.

3 Hub Tension Nut
4 Wire Spool

Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.

5 Push Roll/Lower Drive Roll
6 Drive Roll Pressure Adjustment Opening
7 Drive Roll Release Lever (Red)
8 Wire Inlet Guide
9 Contact Tip
10 Nozzle

Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm).

Release red lever.

| | | |---|---| | | |

Turn On welding power source power.

Install contact tip and nozzle. Reinstall spool cover and thumb screw.

|Wood| |---|

Cut off wire.Press gun trigger to feed wire to check drive roll pressure. Turn screw enough to prevent slipping.

Drive roll pressure is preset for .030/.035 aluminum wire. Rotating screw clockwise decreases drive roll pressure and counterclockwise increases pressure.

4

1

5

6 7 8

10

9

3

2|804 985-A

Tools Needed: cover.

3 Hub Tension Nut
4 Wire Spool

Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.

5 Push Roll/Lower Drive Roll
6 Drive Roll Pressure Adjustment Opening
7 Drive Roll Release Lever (Red)
8 Wire Inlet Guide
9 Contact Tip
10 Nozzle

Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm).

Release red lever.

| | | |---|---| | | |

Turn On welding power source power.

Install contact tip and nozzle. Reinstall spool cover and thumb screw.

|Wood| |---|

Cut off wire.Press gun trigger to feed wire to check drive roll pressure. Turn screw enough to prevent slipping.

Drive roll pressure is preset for .030/.035 aluminum wire. Rotating screw clockwise decreases drive roll pressure and counterclockwise increases pressure.

4

1

5

6 7 8

10

9

3

2|804 985-A

Tools Needed: cover.

3 Hub Tension Nut
4 Wire Spool

Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.

5 Push Roll/Lower Drive Roll
6 Drive Roll Pressure Adjustment Opening
7 Drive Roll Release Lever (Red)
8 Wire Inlet Guide
9 Contact Tip
10 Nozzle

Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm).

Release red lever.

| | | |---|---| | | |

Turn On welding power source power.

Install contact tip and nozzle. Reinstall spool cover and thumb screw.

|Wood| |---|

Cut off wire.Press gun trigger to feed wire to check drive roll pressure. Turn screw enough to prevent slipping.

Drive roll pressure is preset for .030/.035 aluminum wire. Rotating screw clockwise decreases drive roll pressure and counterclockwise increases pressure.

4

1

5

6 7 8

10

9

3

2|804 985-A

Tools Needed: cover.

3 Hub Tension Nut
4 Wire Spool

Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.

5 Push Roll/Lower Drive Roll
6 Drive Roll Pressure Adjustment Opening
7 Drive Roll Release Lever (Red)
8 Wire Inlet Guide
9 Contact Tip
10 Nozzle

Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm).

Release red lever.

| | | |---|---| | | |

Turn On welding power source power.

Install contact tip and nozzle. Reinstall spool cover and thumb screw.

|Wood| |---|

Cut off wire.Press gun trigger to feed wire to check drive roll pressure. Turn screw enough to prevent slipping.

Drive roll pressure is preset for .030/.035 aluminum wire. Rotating screw clockwise decreases drive roll pressure and counterclockwise increases pressure.

4

1

5

6 7 8

10

9

3

2|804 985-A

Tools Needed: cover.

3 Hub Tension Nut
4 Wire Spool

Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.

5 Push Roll/Lower Drive Roll
6 Drive Roll Pressure Adjustment Opening
7 Drive Roll Release Lever (Red)
8 Wire Inlet Guide
9 Contact Tip
10 Nozzle

Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm).

Release red lever.

| | | |---|---| | | |

Turn On welding power source power.

Install contact tip and nozzle. Reinstall spool cover and thumb screw.

|Wood| |---|

Cut off wire.Press gun trigger to feed wire to check drive roll pressure. Turn screw enough to prevent slipping.

Drive roll pressure is preset for .030/.035 aluminum wire. Rotating screw clockwise decreases drive roll pressure and counterclockwise increases pressure.

4

1

5

6 7 8

10

9

3

2|804 985-A

Tools Needed: cover.

3 Hub Tension Nut
4 Wire Spool

Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.

5 Push Roll/Lower Drive Roll
6 Drive Roll Pressure Adjustment Opening
7 Drive Roll Release Lever (Red)
8 Wire Inlet Guide
9 Contact Tip
10 Nozzle

Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm).

Release red lever.

| | | |---|---| | | |

Turn On welding power source power.

Install contact tip and nozzle. Reinstall spool cover and thumb screw.

|Wood| |---|

Cut off wire.Press gun trigger to feed wire to check drive roll pressure. Turn screw enough to prevent slipping.

Drive roll pressure is preset for .030/.035 aluminum wire. Rotating screw clockwise decreases drive roll pressure and counterclockwise increases pressure.

4

1

5

6 7 8

10

9

3

2|804 985-A

Tools Needed: cover.

3 Hub Tension Nut
4 Wire Spool

Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.

5 Push Roll/Lower Drive Roll
6 Drive Roll Pressure Adjustment Opening
7 Drive Roll Release Lever (Red)
8 Wire Inlet Guide
9 Contact Tip
10 Nozzle

Remove nozzle and contact tip. Push and hold red lever. Thread wire through inlet guide, past push roll/drive roll, and out end of gun 2 inches (50 mm).

Release red lever.

| | | |---|---| | | |

Turn On welding power source power.

Install contact tip and nozzle. Reinstall spool cover and thumb screw.

|Wood|

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Open valve on cylinder just before welding.

Close valve on cylinder when finished welding.

3 Spool Gun/MIG Gun Switch Place switch in Spool Gun position.

4 Trigger

Press trigger to energize welding power source contactor, start shielding gas flow, and begin wire feed.

5 Wire Feed Speed Control

Wire feed speed is controlled by welding power source Wire Speed control (see welding power source Owner’s Manual for appropriate setting).

6 Voltage Control

Arc voltage is controlled by welding power source Voltage control (see welding power source Owner’s Manual for appropriate setting).

To purge shielding gas line, set gun selection switch (item 3) to the MIG Gun position. Press spool gun trigger to energize gas valve. Shielding gas will flow, but spool gun will not feed wire. Hold trigger in for several seconds to purge gas line. Return gun selection switch to the Spool Gun position before welding.

sb5.1* 6/92 − S-0621-C / Ref. 804 755-B / Ref. 804 986-A / 804 476-C

B. Weld Parameters For Renegade 180 Model

|Select Wire Type, Polarity, and Shielding Gas|Wire Size|Material Thickness|Material Thickness|Material Thickness|Material Thickness|Material Thickness|Material Thickness|Material Thickness|Material Thickness| |---|---|---|---|---|---|---|---|---|---| |Select Wire Type, Polarity, and Shielding Gas|Wire Size|20 ga|18 ga|16 ga|14 ga|1/8 in.|3/16 in.|1/4 in.|5/16 in.| | |Shop Settings (Wall or Premise Power, 230 V 1 Ph)

|Shop Settings (Wall or Premise Power, 230 V 1 Ph)

|Shop Settings (Wall or Premise Power, 230 V 1 Ph)

|Shop Settings (Wall or Premise Power, 230 V 1 Ph)

|Shop Settings (Wall or Premise Power, 230 V 1 Ph)

|Shop Settings (Wall or Premise Power, 230 V 1 Ph)

|Shop Settings (Wall or Premise Power, 230 V 1 Ph)

|Shop Settings (Wall or Premise Power, 230 V 1 Ph)

|Shop Settings (Wall or Premise Power, 230 V 1 Ph)

| |Aluminum 4043 (DCEP) 100% Argon Shielding Gas|0.030| |2.0/70|2.0/70|4.0/70|5.0/70|8.0/95|10/100| | |Aluminum 4043 (DCEP) 100% Argon Shielding Gas|0.035| | |2.5/65|4.0/60|5.0/65|8.0/90|10/90| | | |Field Setting (Generator Power)

|Field Setting (Generator Power)

|Field Setting (Generator Power)

|Field Setting (Generator Power)

|Field Setting (Generator Power)

|Field Setting (Generator Power)

|Field Setting (Generator Power)

|Field Setting (Generator Power)

|Field Setting (Generator Power)

| |Aluminum 4043 (DCEP) 100% Argon Shielding Gas|0.030| |4.0/70|4.0/70|6.0/70|10/75| | | | |Aluminum 4043 (DCEP) 100% Argon Shielding Gas|0.035| | |4.5/60|6.0/60|10/65| | | |

|Notes| |---|

| |MATERIAL THICKNESS REFERENCE CHART| |---|---| | | | | |24 Gauge (.025 in)| | |22 Gauge (.031 in)| | |20 Gauge (.037 in) 18 Gauge (.050 in)| | |16 Gauge (.063 in)| | |14 Gauge (.078 in)|

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1 Nozzle

2 Contact Tip

3 Liner Remove and replace liner. Reinstall parts as shown.

Tools Needed:

Ref. 804 985-A

######### 5-4. Troubleshooting

|Trouble|Remedy| |---|---| | | | |No weld output; gun/feeder does not work.|Place Power switch on welding power source in the On position (see welding power source Owner’s Manual). Check Spool Gun/MIG Gun switch for correct position.| |Erratic weld output.|Tighten and clean all connections.| |Erratic weld output.|Check for proper weld output polarity connections (see Section 4-1A, 3-4 or 3-5).| |Pressing gun/feeder trigger does not energize welding power source; welding wire is not energized; shielding gas does not flow.|Secure plug from gun/feeder trigger cord into 4-socket receptacle on welding power source (see Section 3-3B, 3-4 or 3-5).| |Pressing gun/feeder trigger does not energize welding power source; welding wire is not energized; shielding gas does not flow.|Place Spool Gun/MIG Gun switch in Spool Gun position (see Section 3-3B or 3-5).| |Wire feeds, shielding gas flows, but welding wire is not energized.|Secure spool gun cable connector to wire drive assembly inside welding power source (see Section 3-3B, 3-4 or 3-5).| |Wire feeds, shielding gas flows, but welding wire is not energized.|See Troubleshooting section in welding power source Owner’s Manual.| |Wire feeds erratically.|Check and correct drive roll pressure (see Section 3-6).| |Wire feeds erratically.|Clean or replace drive roll; clean or replace liner (see Sections 5-2 and 5-3).|

5-5. GMAW (MIG) Aluminum Welding Hints Here are several hints to help you be more successful with your new aluminum feed system. MIG welding aluminum requires different techniques than MIG welding mild steel.

############ A. Before You Start Welding

The removal of lubricants from the aluminum base material may be necessary. Consult with your local welding distributor for their recommendation on aluminum cleaners.

Oxide removal should be done after degreasing. This should be done with a stainless steel wire brush. This can be done with a hand wire brush or with a cup wire brush. If a power wire brush is used, keep the RPM’s and pressures low to reduce smearing the surface of the material, which could entrap oxides and impurities under the surface. Always use a wire brush that is used only on aluminum to keep from contaminating the base material.

Contact you local welding distributor or aluminum filler metal representative for recommendations on wire alloys that fit your application. Know the alloy of your base aluminum and what conditions the finished part will be subjected to. The two most readily available aluminum filler wires are ER4043 and ER5356.

############# B. Welding TechniquesMake sure the welding power source is set up to weld DCEP (DC Electrode Positive).

For MIG welding aluminum you need to use a 10 to 15 degree push travel angle (tip and nozzle pointing in the direction of travel). See Figure 5-1.

|10°-15°

Side View Of Gun Tip Angle

10°-15°

Direction Of Welding Forehand (Push) Technique

Backhand (Drag) Technique| |---|

############ Figure 5-1. Gun Tip Angle

Pulling or using a drag angle will produce porous, dirty welds due to a lack of gas coverage. The reflective heat and weld puddle that is present when MIG welding aluminum is very hot. Holding the tip closer than 3/4 in. could lead to the wire burning back to the contact tip and other feeding problems. The most common shielding gas for MIG welding aluminum is 100% argon. Flow rates of 20 to 30 CFH [cubic feet per hour (0.57 to 0.85 m3/hr)] are acceptable. C25 or argon CO2 shielding gases are not acceptable.

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4. 6 Months — Batteries

5. 90 Days — Parts

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

MIG Guns/TIG Torches and Subarc (SAW) Guns

miller_warr 2007−01

Owner’s Record

Please complete and retain with your personal records.

############# Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

######## Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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

To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller

Contact the Delivering Carrier to:

File a claim for loss or damage during shipment.

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

|Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA

International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125

European Headquarters − United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066

www.MillerWelds.com

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