Visit our website at
www.MillerWelds.com
Millermatic 185
And M-15 Gun
Processes
Description
R
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Arc Welding Power Source
And Wire Feeder
OM-1313C April 1997
Eff. w/Serial Number KH376829
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
For practical information on
welding, process applica-
tions, and Miller products,
visit our website at
www.millerwelds.com
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
The following terms are
used interchangeably
throughout this manual:
MIG = GMAW
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Volt-Ampere Curves 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Duty Cycle And Overheating 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Installing Work Clamp 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Installing Gas Supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Installing Welding Gun 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Setting Gun Polarity 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Installing Wire Spool And Adjusting Hub Tension 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Changing Input Voltage 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Electrical Service Guide 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. Selecting A Location And Connecting Input Power 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Threading Welding Wire 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. Weld Parameter 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − OPERATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Front Panel Controls 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − MAINTENANCE & TROUBLESHOOTING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Circuit Breakers CB1 And CB2 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Changing Drive Roll And Inlet Wire Guide 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Cleaning Or Replacing Gun Liner 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Replacing Switch And/Or Head Tube 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Replacing Gun Contact Tip 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Unicable Repair 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Troubleshooting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − ELECTRICAL DIAGRAM 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MIG WELDING (GMAW) GUIDELINES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Typical MIG Process Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Typical MIG Process Control Settings 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Holding And Positioning Welding Gun 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Conditions That Affect Weld Bead Shape 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Gun Movement During Welding 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Poor Weld Bead Characteristics 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Good Weld Bead Characteristics 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Troubleshooting − Excessive Spatter 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Troubleshooting − Porosity 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Troubleshooting − Excessive Penetration 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Troubleshooting − Lack Of Penetration 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Troubleshooting − Incomplete Fusion 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Troubleshooting − Burn-Through 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14. Troubleshooting − Waviness Of Bead 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15. Troubleshooting − Distortion 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-16. Common MIG Shielding Gases 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
OM-1313C
OM-1313 Page 1
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
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
Y 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 1-4. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y 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.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D 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).
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 proper grounding conduc-
tor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable − do not use work clamp or work cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D 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 if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-1313 Page 2
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.
ARC RAYS can burn eyes and skin.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
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.
WELDING can cause fire or explosion.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D 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).
D 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 and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding 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 lighter or matches,
from your person before doing any welding.
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
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
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.
CYLINDERS can explode if damaged.
D Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
OM-1313 Page 3
1-3. Additional Symbols for Installation, Operation, and Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
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
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Be sure this welding machine is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-1313 Page 4
1-5. 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 electro-
magnetic 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 power-
frequency 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.
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 opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-1313 Page 5
SECTION 2 − INSTALLATION
2-1. Specifications
Rated Welding
Output
Amperage
Range
Maximum
Open-Circuit
Voltage DC
Amperes Input at
Rated Load
Output, 60 Hz,
Single-Phase
Weight
Overall
Dimensions
Voltage DC
200 V 230 V KVA KW
150 A @ 23 Volts
DC, 60% Duty Cycle
30 − 185 33 30 (1.6)* 26 (1.4)* 6 (0.27)* 5 (0.13)*
165 lb
(75 kg)
Length: 36 in
(915 mm)
Width: 18 in
(457 mm)
Height: 27 in
(686 mm)
Wire Type And Diameter
Calculated Wire Speed
Max Wire Feed Speed
Solid Steel /
Stainless Steel
Flux Cored Aluminum
Calculated Wire Speed
Range At No Load
Max Wire Feed Speed
While Welding
.023 − .035 in
(0.6 - 0.9 mm)
.030 − .045 in
(0.8 − 1.2 mm)
.030 − .035 in
(0.8 − 0.9 mm)
138 − 795 IPM (3.5 − 20.3 m/min) 650 IPM (16.5 m/min)
*While idling
2-2. Volt-Ampere Curves
va_curve1 4/95 − SB-180 824
Volt-ampere curves show mini-
mum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall be-
tween curves shown.
OM-1313 Page 6
6 Minutes Welding 4 Minutes Resting
2-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
Overheating
0
15
A or V
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − SB-181 009
60% Duty Cycle At 150 Amperes
OM-1313 Page 7
2-4. Installing Work Clamp
1 Work Cable
2 Boot
Slide boot onto work cable. Route
cable out front panel opening from
inside.
3 Negative (−) Output Terminal
Connect cable to terminal and
cover connection with boot.
4 Hardware
5 Work Clamp
Route cable through clamp handle
and secure as shown.
Close door.
ST-801 566
1/2, 3/4 in
1
2
3
4
5
Tools Needed:
2-5. Installing Gas Supply
ST-801 571 / Ref. ST-109 492
1 Cylinder Rack
2 Chain
Obtain gas cylinder and chain cylin-
der to rack.
3 Gas Hose Fitting
4CO
2
Washer
5 Regulator
Install washer and regulator onto
cylinder.
6 Gas Hose Connection
Obtain gas hose with fittings and
install between regulator and
welding power source.
7 Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour).
56
7
4
1
2
3
5/8, 1-1/8 in
Tools Needed:
OM-1313 Page 8
2-6. Installing Welding Gun
Ref. ST-801 567
1 Drive Assembly
2 Gun Securing Knob
3 Gun End
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
nut.
4 Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
Close door.
2
1
3
4
2-7. Setting Gun Polarity
1 Polarity Changeover Label
(Located Near Drive
Assembly)
Always read and follow manufac-
ture’s recommended polarity.
1
3/4, 11/16 in
Wire Drive Assembly Lead
To Positive (+) Output Terminal
Work Clamp Lead To
Negative (−) Output Terminal
GUN POLARITY
CHANGEOVER CONNECTIONS
Reverse Lead Connections − For Electrode
Negative (DCEN) For Flux Cored Wires
(FCAW Process). Drive Assembly
Becomes Negative
S-144 449-D
Tools Needed:
OM-1313 Page 9
2-8. Installing Wire Spool And Adjusting Hub Tension
ST-072573-B
When a slight force is needed
to turn spool, tension is set.
15/16 in
Use compression spring with
8 in (200 mm) spools.
Tools Needed:
2-9. Changing Input Voltage
ST-801 580-A
Y Turn Off unit, and disconnect
input power.
Unit was shipped from factory set
for 230 volts.
1 Transformer T1
2 Rear Of Power Switch S1
3 Lead Marked 230 Volt And
Fan Motor Lead
Disconnect 230 volt lead and fan
motor lead from rear of S1. Leave
fan motor lead connected to 230
volt lead.
4 Lead Marked 200 Volt
Remove cable tie, and slide short
piece of sleeving off 200 volt lead,
and slide sleeving over end of 230
volt and fan motor leads. Fold
sleeving over and secure in place.
Connect 200 volt lead to S1 where
230 volt lead was removed.
Reinstall wrapper.
3/8, 7/16 in
1
Tools Needed:
2
3
4
OM-1313 Page 10
2-10. Electrical Service Guide
Input Voltage
200 230
Input Amperes At Rated Output
30 26
Max Recommended Standard Fuse Or Circuit Breaker Rating In
Amperes
45 40
Min Input Conductor Size In AWG/Kcmil
10 10
Max Recommended Input Conductor Length In Feet (Meters)
97 (29) 128 (39)
Min Grounding Conductor Size In AWG/Kcmil
10 10
Reference: 1996 National Electrical Code (NEC). S-0092-J
2-11. Selecting A Location And Connecting Input Power
1 Rating Label
Supply correct input power.
2 Plug
3 Receptacle
Connect plug to receptacle.
4 Input And Grounding
Conductors
Connect directly to line disconnect
device if hard wiring is required.
5 Line Disconnect Device
See Section 2-10.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
ST-801 568
L1
L2
230 VAC, 1
18 in (457 mm) of
space for airflow
L1
L2
1
Y Always connect grounding
conductor first.
= GND/PE
Y Do not move or operate unit
where it could tip.
4
2
3
1
5
OM-1313 Page 11
2-12. Installing Drive Roll, Inlet Wire Guide, And Threading Welding Wire
Ref. ST-801 570 / ST-801 083 / S-0627-A
6 in
(150 mm)
4 in
(102 mm)
Tighten
WOOD
Open pressure assembly. Pull and hold wire; 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 out of gun. Reinstall
contact tip and nozzle.
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close
and latch door.
Tools Needed:
OM-1313 Page 12
2-13. Weld Parameter
Wire Type,
Wire
Material Thickness
Wire Type,
Shielding Gas,
And Flow Rate
Wire
Diameter
(inch)
Operator
Controls
3/8 in
(9.5
mm)
1/4 in
(6.4
mm)
3/16 in
(4.8
mm)
1/8 in
(3.2
mm)
12 ga 14 ga 16 ga 18 ga 20 ga 22 ga
.023
Voltage Tap − − 6 5 4 3 3 2 1 1 − −
.023
Wire Speed − − 100 90 70 65 60 40 25 20 − −
E70S-6
CO
2
.030
Voltage Tap − − 4 4 3 2 2 2 1 − − − −
CO
2
20 cfh+
.030
Wire Speed − − 70 60 50 45 40 30 25 − − − −
.035
Voltage Tap 6 4 4 3 3 2 2 1 − − − −
.035
Wire Speed 80 65 40 35 30 25 30 10 − − − −
.023
Voltage Tap − − 3 4 3 3 2 2 1 1 1
.023
Wire Speed − − 80 90 70 60 70 40 45 25 12
E70S-6
75% Argon
.030
Voltage Tap 6 4 4 3 3 2 2 1 1 − −
75% Argon
25% CO
2
20 cfh+
.030
Wire Speed 90 58 70 55 50 48 45 30 5 − −
20 cfh+
.035
Voltage Tap 6 4 4 3 3 2 2 1 1 − −
.035
Wire Speed 80 48 60 50 35 27 30 11 3 − −
.030
Voltage Tap 5 4 4 3 2 2 1 1 − − − −
E71T-GS
Flux Core
.030
Wire Speed 80 65 65 50 30 30 10 5 − − − −
E71T-GS
Flux Core
.035
Voltage Tap 5 4 3 2 2 2 1 1 − − − −
.035
Wire Speed 5 50 40 30 25 20 10 0 − − − −
.023
Voltage Tap 5 4 4 4 3 3 3 2 2 2
.023
Wire Speed 95 85 80 60 50 50 50 30 20 20
ER 308
Stainless Steel
.030
Voltage Tap 5 5 4 3 3 2 2 2 1 − −
Stainless Steel
Tri-Mix
20 cfh+
.030
Wire Speed 70 70 70 50 45 50 45 40 0 − −
20 cfh+
.035
Voltage Tap 6 5 5 4 3 2 2 2 − − − −
.035
Wire Speed 65 40 40 30 30 25 20 10 − − − −
*Do not change Voltage switch position while welding Wire Speed value in Table is a starting value only, and Wire Speed control setting can be fine
tuned during welding. S-181 020-A
OM-1313 Page 13
SECTION 3 − OPERATION
3-1. Front Panel Controls
Ref. ST-180 930
Controls For Standard Units
1 Wire Speed Control
Use control to select a wire feed
speed. Scale around control is not
actual wire feed speed, but is for
reference only.
2 Voltage Switch
The higher the selected number,
the thicker the material that can be
welded (see Section 2-13). Do not
switch under load.
3 Pilot Light
4 Power Switch
1
2
3
4
OM-1313 Page 14
SECTION 4 − MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance
Y Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Replace
Damaged Or
Unreadable
Labels
Clean And
Tighten
Weld
Terminals
Repair Or
Replace
Cracked
Cables And
Cords
6 Months
Blow Out Or
Vacuum Inside
4-2. Circuit Breakers CB1 And CB2
Ref. ST-801 567
Y Turn Off unit.
1 Circuit Breaker CB1
CB1 protects the transformer from
overload. If CB1 opens, wire
feeding stops.
2 Circuit Breaker CB2
CB2 protects the trigger circuit from
overload. If CB1 opens, weld output
stops.
Press button to reset circuit
breaker. Close door.
1
2
4-3. Changing Drive Roll And Inlet Wire Guide
Ref. ST-801 569
1 Drive Roll
Choose correct drive roll for wire
type, and install as shown.
2 Inlet Wire Guide
Remove guide by pressing on
barbed area, or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.
Tools Needed:
2
1
3/32 in
OM-1313 Page 15
4-4. Cleaning Or Replacing Gun Liner
Ref. ST-800 797-A
3/8 in
To Reassemble Gun:
Insert new liner.
Install and tighten wire outlet guide.
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.
Lay gun cable out straight
before installing new liner.
Head tube
3/8 in
Wire Outlet Guide
Remove liner.
Remove nozzle, contact tip,
adapter, and wire outlet guide.
Blow out gun casing.
Y Disconnect gun first.
Tools Needed:
OM-1313 Page 16
4-5. Replacing Switch And/Or Head Tube
Ref. ST-800 795-A
Do not disturb cable connection between
cable connector and connector nut.
1 Remove handle
locking nut.
2 Remove switch housing. Note: If installing new
switch, push switch lead connectors onto terminal of
new switch (polarity is not important). Install switch
back into handle, and secure with handle locking nut.
If replacing head tube, continue to end of figure.
3 Slide handle.
4 Secure head
tube in vice.
5 Remove shock wash-
ers from front and
rear of head tube.
6 Loosen jam nut. Remove
from vice and turn head
tube out by hand.
7 Install both existing shock washers
to new head tube and hand-tighten
head tube into connector cable.
8 Place head tube in vice and tighten
to within 1/8 in (3.2 mm) spacing be-
tween connector cable and body.
9 Remove from vice. Reposition
handle and install switch housing.
Secure with handle locking nut.
Y Disconnect gun first.
3/4 in
Tools Needed:
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