Miller MF100270T Owner's manual

Spoolmatic 15A

Processes

Description

MIG (GMAW) Welding

Feeder Gun

OM-1213 137 531AM

2015−04

Visit our website at

www.MillerWelds.com

File: MIG (GMAW)

And 30A

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

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.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 2009−09

TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING 1......

1-1. Symbol Usage 1.......................................................................

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

1-3. Proposition 65 Warnings 2...............................................................

1-4. Principal Safety Standards 2.............................................................

1-5. EMF Information 2.....................................................................

SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT

UTILISATION 3..............................................................................

2-1. Signification des symboles 3.............................................................

2-2. Dangers relatifs au soudage à l’arc 3......................................................

2-3. Proposition californienne 65 Avertissements 4..............................................

2-4. Principales normes de sécurité 4.........................................................

2-5. Informations relatives aux CEM 4.........................................................

SECTION 3 − DEFINITIONS 5..................................................................

3-1. Additional Safety Symbols And Definitions 5................................................

3-2. Miscellaneous Symbols And Definitions 5..................................................

SECTION 4 − SPECIFICATIONS 6..............................................................

4-1. Unit Specifications 6....................................................................

4-2. Environmental Specifications 6...........................................................

SECTION 5 − INSTALLATION 6................................................................

5-1. Removing Top Cover 6..................................................................

5-2. Installing Wire Spool And Threading Welding Wire 7.........................................

5-3. Rotating Canister 7.....................................................................

5-4. Connecting To 24 Volt Weld Control 8.....................................................

5-5. Connecting To 115 Volt Weld Control 8....................................................

5-6. Installing Gas Supply 9.................................................................

5-7. Adjusting Drive Roll And Spool Brake Pressure 10...........................................

SECTION 6 − OPERATION 11...................................................................

6-1. Controls 11............................................................................

6-2. Shielding Gas 11........................................................................

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 12.........................................

7-1. Routine Maintenance 12.................................................................

7-2. Changing Gun Contact Tip 12.............................................................

7-3. Replacing Head Tube Liner 13............................................................

7-4. Gun Drive Assembly Maintenance 14......................................................

7-5. Replacing Canister Inlet Guide 15.........................................................

7-6. Replacing Spool Canister 15..............................................................

7-7. Replacing Diffuser 16....................................................................

7-8. Troubleshooting 16......................................................................

SECTION 8 − ELECTRICAL DIAGRAM 17........................................................

SECTION 9 − PARTS LIST 18...................................................................

SECTION 10 − PARTS LIST INCLUDING CONSUMABLES 21.......................................

WARRANTY

OM-1213 Page 1

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW

WELDING GUNS − READ BEFORE USING

SR7 (MIG) 2013-09

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

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 ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols 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 welding power source Owner’s Manual. 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.

D Always wear dry insulating gloves.

D Insulate yourself from work and ground.

D Do not touch live electrode or electrical parts.

D Replace worn, damaged, or cracked guns or cables.

D Turn off welding power source before changing contact tip or gun

parts.

D Keep all covers and handle securely in place.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes.

D Ventilate area, or use breathing device. The

recommended way to determine adequate

ventilation is to sample for the composition and quantity of fumes

and gases to which personnel are exposed.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

WELDING can cause fire or explosion.

D Do not weld near flammable material.

D Do not weld on containers that have held com-

bustibles, or on closed containers such as

tanks, drums, or pipes unless they are properly prepared ac-

cording to AWS F4.1 and AWS A6.0 (see Safety Standards).

D Watch for fire; keep extinguisher nearby.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in

use.

D Always ventilate confined spaces or use ap-

proved air-supplied respirator.

MOVING PARTS can injure.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

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 an approved welding helmet fitted with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks

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,

glare and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame-resistant material

(leather, heavy cotton, wool). Body protection includes oil-free

clothing such as leather gloves, heavy shirt, cuffless trousers, high

shoes, and a cap.

HOT PARTS can burn.

D Allow gun to cool before touching.

D Do not touch hot metal.

D Protect hot metal from contact by others.

OM-1213 Page 2

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Check for noise level limits exceeding those

specified by OSHA.

D Use approved ear plugs or ear muffs if noise level is high.

D Warn others nearby about noise hazard.

WELDING WIRE can injure.

D Keep hands and body away from gun tip when

trigger is pressed.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or

servicing unit. Read the safety information at

the beginning of the manual and in each

section.

D Use only genuine replacement parts from the manufacturer.

D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local

codes.

1-3. Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known to

the state of California to cause cancer, birth defects, or other

reproductive harm. Wash hands after use.

1-4. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

is available as a free download from the American Welding Society at

http://www.aws.org or purchased from Global Engineering Documents

(phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website: www.glo-

bal.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com-

bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: 1-877-413-5184,

website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 14501 George Carter Way, Suite

103, Chantilly, VA 20151 (phone: 703-788-2700, website:

www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—

phone for Region 5, Chicago, is 312-353-2220, website:

www.osha.gov).

1-5. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). The current from arc welding (and allied pro-

cesses including spot welding, gouging, plasma arc cutting, and induc-

tion heating operations) creates an EMF field around the welding circuit.

EMF fields may interfere with some medical implants, e.g. pacemakers.

Protective measures for persons wearing medical implants have to be

taken. For example, restrict access for passers−by or conduct individu-

al risk assessment for welders. All welders should use the following pro-

cedures in order to minimize exposure to EMF fields from the welding

circuit:

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

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

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

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.

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

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

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 recom-

mended.

OM-1213 Page 3

SECTION 2 − MESURES DE SÉCURITÉ VISANT LES

PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT

UTILISATION

SR7(MIG)_2013−09 fre

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives

aux précautions de sécurité et au mode opératoire.

2-1. Signification des symboles

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 dan-

gers 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.

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 présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les ris-

ques de danger. Lorsque vous voyez un symbole, soyez vigi-

lant et suivez les directives mentionnées afin d’éviter tout

danger. Les consignes de sécurité présentées ci-après ne

font que résumer l’information contenue dans les normes de

sécurité énumérées dans le manuel d’utilisation du poste de

soudage. Veuillez lire et respecter toutes ces normes de sé-

curité.

L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

D Porter toujours des gants secs et isolants.

D S’isoler de la pièce et de la terre.

D Ne jamais toucher une électrode ou des pièces

électriques sous tension.

D Remplacer les pistolets ou câbles de soudage qui sont endom-

magés, usés ou craquelés.

D Mettre la soudeuse hors tension avant de remplacer un bec

contact ou des pièces de pistolet.

D S’assurer que tous les couvercles et poignées sont fermement

assujettis.

LES VAPEURS ET LES FUMÉES

peuvent être nocives.

D Éloigner sa tête des endroits renfermant des

vapeurs.

D Aérer la zone de travail ou porter un appareil

respiratoire. Pour déterminer la bonne venti-

lation, il est recommandé de procéder à un pré-

lèvement pour la composition et la quantité de

fumées et de gaz auxquels est exposé le

personnel.

D Lire et comprendre les fiches de données de sécurité et les

instructions du fabricant concernant les adhésifs, les revête-

ments, les nettoyants, les consommables, les produits de ref-

roidissement, les dégraisseurs, les flux et les métaux.

LE SOUDAGE peut causer un in-

cendie ou une explosion.

D Ne pas souder à proximité de matériaux inflam-

mables.

D 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 et AWS A6.0

(voir les Normes de Sécurité).

D Prendre garde aux incendies et toujours avoir un extincteur à

proximité.

D Lire et comprendre les fiches de données de sécurité et les

instructions du fabricant concernant les adhésifs, les

revêtements, les nettoyants, les consommables, les produits de

refroidissement, les dégraisseurs, les flux et les métaux.

L’ACCUMULATION DE VAPEURS

peut causer des lésions ou la mort.

D Quand on n’utilise pas le gaz comprimé de pro-

tection, fermer le robinet de la bouteille.

D Assurer toujours la ventilation des zones fermées ou utiliser un

appareil respiratoire avec alimentation en air.

Les PIÈCES MOBILES peuvent

causer des blessures.

D Ne pas s’approcher des organes mobiles.

D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LE RAYONNEMENT DE L’ARC peut

brûler les yeux et la peau.

Le rayonnement de l’arc du procédé de soudage

génère des rayons visibles et invisibles intenses

(ultraviolets et infrarouges) susceptibles de provoquer des brûlures

dans les yeux et sur la peau. Des étincelles sont projetées pendant le

soudage.

D 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).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

D 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.

OM-1213 Page 4

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du

corps comporte des vêtements sans huile comme par ex. des

gants de cuir, une chemise solide, des pantalons sans revers, des

chaussures hautes et une casquette.

LES PIÈCES CHAUDES peuvent

provoquer des brûlures.

D Laisser refroidir le pistolet avant de le toucher.

D Ne pas toucher d’objets métalliques chauds.

D Abriter les objets métalliques contre tout

contact par les personnes à proximité.

Le BRUIT peut endommager l’ouie.

Le bruit des processus et des équipements peut

affecter l’ouïe.

D Vérifier si les niveaux de bruit excèdent les limites spécifiées par

l’OSHA.

D Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés si

le niveau de bruit est élevé.

D Avertir les personnes à proximité au sujet du danger inhérent au

bruit.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

D Éloigner les mains et le corps de la buse du

pistolet après avoir appuyé sur la gâchette.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant

l’installation, l’utilisation ou l’entretien de

l’appareil. Lire les informations de sécurité au

début du manuel et dans chaque section.

D N’utiliser que les pièces de rechange recommandées par le cons-

tructeur.

D Effectuer l’entretien en respectant les manuels d’utilisation,

les normes industrielles et les codes nationaux, d’état et locaux.

2-3. 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)

Ce produit contient des éléments chimiques, dont le plomb,

reconnus par l’État de Californie pour leur caractère

cancérogène ainsi que provoquant des malformations

congénitales ou autres problèmes de procréation. Se laver

les mains après toute manipulation.

2-4. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

is available as a free download from the American Welding Society at

http://www.aws.org or purchased from Global Engineering Documents

(phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website: www.glo-

bal.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com-

bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: 1-877-413-5184,

website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 14501 George Carter Way, Suite 103,

Chantilly, VA 20151 (phone: 703-788-2700, website: www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: 1-800-344-3555, website: 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, Superinten-

dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone:

1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region

5, Chicago, is 312-353-2220, website: www.osha.gov).

2-5. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs

électromagnétiques (CEM) à certains endroits. Le courant de soudage

crée un CEM autour du circuit et du matériel de soudage. Le courant

issu d’un soudage à l’arc (et de procédés connexes, y compris le

soudage par points, le gougeage, le découpage plasma et les

opérations de chauffage par induction) crée un champ

électromagnétique (CEM) autour du circuit de soudage. Des mesures

de protection pour les porteurs d’implants médicaux doivent être prises:

Limiter par exemple tout accès aux passants ou procéder à une

évaluation des risques individuels pour les soudeurs. Tous les

soudeurs doivent appliquer les procédures suivantes pour minimiser

l’exposition aux CEM provenant du circuit de soudage:

1 Rassembler les câbles en les torsadant ou en les attachant avec

du ruban adhésif ou avec une housse.

2 Ne pas se tenir au milieu des câbles de soudage. Disposer les

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

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

corps.

4 Maintenir la tête et le torse aussi loin que possible du matériel du

circuit de soudage.

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

soudure.

6 Ne pas travailler à proximité d’une source de soudage, ni

s’asseoir ou se pencher dessus.

7 Ne pas souder tout en portant la source de soudage ou le

dévidoir.

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 pro-

cédures précédentes.

OM-1213 Page 5

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe1 2012−05

3-2. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.

Amperes

Duty Cycle

Primary Voltage

Volts

Rated Welding

Current

Conventional

Load Voltage

Degree Of

Protection

Percent

Primary Current

Notes

OM-1213 Page 6

SECTION 4 − SPECIFICATIONS

4-1. Unit Specifications

Wire Diameter

Range

Approximate

Wire Feed

Range

Cooling

Method

Maximum

Spool Size

Weld Circuit Rating

Overall

Dimensions

Weight

.025 Thru 1/16 in.

(0.6 Thru 1.6 mm)

Aluminum Wire

.025 Thru .045 in.

(0.6 Thru 1.1 mm)

Hard Or Cored Wire

70 To 875 ipm

(1.7 To 22.2

mpm)

Air Cooled

4 in. (102 mm)

Diameter

100 Volts, 200 Amperes,

100% Duty Cycle

Using Argon Shielding Gas

Length: 15-3/8 in.

(390 mm)

Width: 2-1/2 in.

(64 mm)

Height: 10-3/4 in.

(273 mm)

2.9 lb

(1.3 kg) Gun

Only

15A Model:

9 lb (4.1 kg)

Gun With Cable

30A Model:

14 lb (6.4 kg)

Gun With Cable

4-2. Environmental Specifications

A. IP Rating

IP Rating

IP23

This equipment is designed for outdoor use. It may be stored,

but is not intended to be used for welding outside during precipitation unless sheltered.

IP23 2014−06

SECTION 5 − INSTALLATION

. Use weld control or welding power source Owner’s Manual during gun installation. If contact tip, liner, and drive roll groove are not correct for wire

size and type, see Section 7 to change parts as needed. See Parts List for other available contact tips.

5-1. Removing Top Cover

150 882-G

1 Top Cover Triangular Boss

Push up on triangular boss to open

door. Door hinges on handle.

To open door fully, push up on door

until it clicks into position.

. If door is pushed too far it will

separate from handle. If this

happens the door can be rein-

stalled.

Push door back into original posi-

tion to close.

OM-1213 Page 7

5-2. Installing Wire Spool And Threading Welding Wire

150 436-F

1 Top Cover

2 Canister

3 Canister Cover

4 Thumbscrew (Canister Cover)

Loosen thumbscrew and remove

cover.

5 Wire Spool

Loosen wire from spool, cut off bent

wire, and pull 6 in. (150 mm) of wire

off spool.

6 Pressure Roll Assembly

Lift arm and open pressure roll

assembly.

7 Canister Inlet Guide

8 Drive Roll Groove

. For wire sizes .035 in. (0.9 mm)

and smaller use small groove,

and .047 in. (1.2 mm) and 1/16

in (1.6 mm) use large groove.

9 Contact Tip

Thread wire through canister inlet

guide, along drive roll groove, and

out contact tip.

Install spool so wire feeds off

bottom.

10 Spool Brake Thumbnut

If necessary, turn thumbnut coun-

terclockwise slightly to install spool.

11 Thumbscrew (Canister

Rotation)

Loosen thumbscrew to rotate can-

ister (see Section 5-3).

Close and secure pressure roll

assembly.

Reinstall top cover and canister

cover.

Tools Needed:

5-3. Rotating Canister

150 433-A

1 Canister

Loosen canister rotation thumb-

screw (see Section 5-2). Move can-

ister to desired position. Tighten

thumbscrew.

Rear View

OM-1213 Page 8

5-4. Connecting To 24 Volt Weld Control

150 917-G

1 Gas Hose

Connect fitting to regulator/flowme-

ter (see Section 5-6).

2 24 Volt Weld Control

3 Trigger Control Cord

Insert plug into receptacle, and

tighten threaded collar.

4 Weld Cable

Connect to positive (+) weld output

terminal on welding power source

according to its Owner’s Manual.

Tools Needed:

1-1/8, 5/8 in.

5-5. Connecting To 115 Volt Weld Control

Ref. 149 549-A / 149 966-J

1 115 Volt Weld Control

2 Gas Hose

Connect to regulator/flowmeter.

3 Trigger Control Cord

Insert plug into receptacle, and

tighten threaded collar.

4 Weld Cable

5 Positive (+) Weld Output

Terminal In Control

Connect weld cable to positive (+)

weld output terminal in weld control.

Reinstall weld control wrapper.

Left Side

Wrapper Off

Tools Needed:

1-1/8, 5/8 in.

OM-1213 Page 9

5-6. Installing Gas Supply

ssb3.1* 5/94 − 158 697-A

Obtain gas cylinder and chain to

running gear, wall, or other station-

ary support so cylinder cannot fall

and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve,

and open valve slightly. Gas flow

blows dust and dirt from valve.

Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install so face is vertical.

. Delivery pressure range must

not exceed 60 psi.

5 Gas Hose Connection

Fitting has 5/8-18 right-hand

threads.

6 Flow Adjust

Typical flow rate is 20 cfh (cubic feet

per hour). Check wire manufactur-

er’s recommended flow rate.

Make sure flow adjust is closed

when opening cylinder to avoid

damage to the flowmeter.

7CO

Adapter

8 O-Ring

Install adapter with O-ring between

regulator/flowmeter and CO

cylinder.

Tools Needed:

1-1/8, 5/8 in.

Gas

7 8

Argon Gas

OM-1213 Page 10

5-7. Adjusting Drive Roll And Spool Brake Pressure

Ref. 151 112-F / 147 741-F

1 Top Cover

2 Canister Cover

3 Thumbscrew

Loosen thumbscrew and remove

cover.

4 Spool

Cut welding wire off at contact tip.

Retract wire onto spool and secure.

5 Spool Brake Thumbnut

Grasp spool in one hand and turn

while adjusting spool brake thumb-

nut. When a slight force is needed

to turn spool, tension is set. Do not

overtighten.

Reinstall canister cover. Thread

welding wire (see Section 5-2).

6 Drive Roll Tension Thumbnut

Turn On unit and check drive roll

pressure by feeding wire against a

wood board or concrete surface;

wire should feed steadily without

slipping.

Adjust drive roll tension thumbnut if

necessary. Do not overtighten.

Turn Off unit. Reinstall top cover.

Tools Needed:

WOOD

Adjusting Pressure

OM-1213 Page 11

SECTION 6 − OPERATION

6-1. Controls

Ref. 147 741-F

1 Trigger

Press trigger to energize welding

power source contactor (if applica-

ble), start shielding gas flow, and

begin wire feed.

For shielding gas preflow and post-

flow, lightly press trigger before and

after welding.

2 Wire Speed Control

Use control to adjust wire feed

speed. The numbers in the opening

are not a wire feed speed and are

for reference only.

6-2. Shielding Gas

sb5.1* 6/92 − S-0621-C / Ref. 147 741-F

1 Shielding Gas Cylinder

2 Valve

3 Gun Trigger

Open valve on cylinder just before

welding.

Gun trigger turns weld output and

gas flow on and off. For shielding

gas preflow and postflow, lightly

press trigger before and after

welding.

Close valve on cylinder when fin-

ished welding.

OM-1213 Page 12

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

n = Check Z = Change ~ = Clean l = Replace

* To be done by Factory Authorized Service Agent

Daily

n Check barrel clamp

screws for tightness.

l Repair Or Replace

Cracked Weld Cable

Every

Month

nl Gun Cables ~ Drive Rolls ~ Clean and Tighten

Weld Terminals

Every

Months

l Damaged Or Unread-

able Labels

l Damaged Gas Hose nl Cords

Every

Months

~ Blow out or Vacuum

Inside Unit

7-1. Changing Gun Contact Tip

Ref. 150 437-A

Remove nozzle

1 Nozzle

2 FasTip

Unscrew FasTip.

Install new FasTip.

OM-1213 Page 13

7-2. Replacing Head Tube Liner

Ref. 803 551-C

The standard head tube liner will

accommodate wire diameters from

.030-1/16 wire size.

1 Cover

2 Screw

3 Clamp

Loosen clamp screws and remove

clamp.

4 Head Tube

Remove head tube from gun.

5 Liner

Pull liner out of head tube.

Insert liner into head tube and

reinstall head tube onto gun.

. A twisting motion may be need-

ed to feed liner thru head tube.

5/32 in.

Tool Needed:

Notes

OM-1213 Page 14

7-3. Gun Drive Assembly Maintenance

Ref. 149 967-H / Ref. 800 945-A

Retract wire onto spool.

1 Setscrew

2 Current Pick-Up Tab

This tab helps prevent burnback

caused by welding arcs inside the

contact tip. This tab may be re-

moved to provide an insulated drive

roll. (If tab is removed, a smaller di-

ameter contact tip is recom-

mended. See options in Parts List.)

Lightly grease top of tab before rein-

stalling.

3 Drive Roll

Use wire brush to clean drive roll.

Install drive roll with desired groove

down, and turn drive roll so one set-

screw faces flat side of shaft.

4 Bearing

Use wire brush to clean bearing.

Line up drive roll groove with bear-

ing groove and liner opening. Tight-

en setscrews.

Thread welding wire through gun

(see Section 5-2). Close and se-

cure pressure roll assembly. Adjust

drive roll pressure, if necessary

(see Section 5-7). Reinstall top cov-

er.

Tools Needed:

5/16 in.

OM-1213 Page 15

7-4. Replacing Canister Inlet Guide

Ref. 150 436-D / Ref. 149 967-H

1 Top Cover

2 Pressure Roll Assembly

Cut off welding wire where it enters

pressure roll assembly area.

3 Nozzle

Pull wire out nozzle.

4 Thumbscrew

5 Canister Cover

Loosen thumbscrew and remove

cover.

6 Wire Spool

7 Spool Brake Thumbnut

Loosen thumbnut, retract wire onto

spool, secure, and remove spool.

8 Canister Inlet Guide

Turn counterclockwise to remove.

Install new guide.

Reinstall spool and thread welding

wire (see Section 5-2).

Close pressure roll assembly. Ad-

just spool brake pressure and drive

roll pressure if necessary (see Sec-

tion 5-7).

Reinstall covers.

Tools Needed:

7-5. Replacing Spool Canister

Ref. 149 967-H

1 Top Cover

2 Pressure Roll Assembly

Cut off welding wire where it enters

pressure roll assembly area.

3 Nozzle

Pull wire out nozzle.

4 Thumbscrew (Canister

Rotation)

Turn thumbscrew counterclock-

wise three full turns.

5 Spool Canister

Remove as shown. Push new can-

ister into wire drive housing until ful-

ly seated. Tighten thumbscrew.

Install spool and thread welding

wire (see Section 5-2).

Close pressure roll assembly. Ad-

just spool brake pressure and drive

roll pressure as necessary (see

Section 5-7).

Reinstall covers.

Tools Needed:

OM-1213 Page 16

7-6. Replacing Diffuser

Ref. 803 348-G

Turn Off welding power source.

1 Nozzle

2 FasTip

To remove, see Section 7-1.

3 Diffuser

Remove diffuser and replace.

Tools Needed:

3/8 in.

7-7. Troubleshooting

Trouble Remedy

No weld output; gun/feeder does no

work.

Secure weld control plug in 115 volts AC receptacle (see weld control Owner’s Manual).

Place Power switch on welding power source in the On position (see welding power source Owner’s

Manual).

Erratic weld output. Tighten and clean all connections.

Pressing gun/feeder trigger does not en-

ergize weld control; welding wire is not

energized; shielding gas does not flow.

Secure plug from gun/feeder trigger cord into 10-socket receptacle on weld control (see Sections 5-4 and

5-5).

Wire feeds, shielding gas flows, bu

welding wire is not energized.

Secure control cable leads in weld control (see weld control Owner’s Manual).

See Troubleshooting section in welding power source Owner’s Manual.

Wire feeds erratically. Check and correct drive roll pressure (see Section 5-7).

Clean drive roll or replace drive roll (see Section 7-3).

Decrease spool brake pressure (see Section 5-7).

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Miller MF100270T, SPOOLMATIC 15A, Spoolmatic 30A Owner's manual

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