Miller-electric M-10 Gun User Manual

ProcessesDescriptionArc Welding Power Sourceand Wire FeederOM-1330 220 237H2007−02Millermatic DVIAnd M-10 GunRFlux Cored (FCAW) WeldingMIG (GMAW) Weld

OM-1330 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-1330 Page 72-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanceRisque D’INCENDIE OU D’EXPLO-SION.D Ne

OM-1330 Page 82-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents

OM-1330 Page 9SECTION 3 − DEFINITIONS3-1. Symbols And DefinitionsWire Feed OutputXDuty CycleDo Not SwitchWhile WeldingVVolts Increase On OffGas Metal

OM-1330 Page 104-2. Duty Cycle And OverheatingDuty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating.If unit overhe

OM-1330 Page 114-3. Volt-Ampere CurvesThe volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding power s

OM-1330 Page 124-5. Connecting To Weld Output Terminals803 778-AY Turn off power before connecting toweld output terminals.Y Failure to properly conne

OM-1330 Page 134-7. Installing Welding Gun1 Drive Assembly2 Gun Securing Knob3 Gun EndLoosen securing knob. Insert gunend through opening until it bot

OM-1330 Page 144-9. Installing Gas Supply803 861-BTools Needed:Obtain gas cylinders and chain torunning gear, wall, or otherstationary support so cyli

OM-1330 Page 154-10. Installing MIG Wire Spool and Adjusting Hub TensionWhen a slight force is neededto turn spool, tension is set.15/16 inUse compres

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-1330 Page 164-11. Connecting 1-Phase Input Power For 230 VAC 803 766-B / Ref. 802 443-AY Installation must meet allNational and Local Codes − haveo

OM-1330 Page 174-12. Electrical Service Guide For 230 VAC60 Hz Single PhaseInput Voltage 230Input Amperes At Rated Output 25Max Recommended Standard F

OM-1330 Page 184-14. Selecting A Location And Connecting Input PowerY Special installation may be requiredwhere gasoline or volatile liquidsare presen

OM-1330 Page 194-15. Threading Welding Wire1 Wire Spool2 Welding Wire3 Inlet Wire Guide4 Pressure Adjustment Knob5 Drive Roll6 Outlet Wire Guide7 Gun

OM-1330 Page 204-16. Installing Diverter Valve And Switch For Optional Spool GunRef. 803 906-B / 803 908-ATools Needed:Y Turn Off unit, and disconnect

OM-1330 Page 214-17. Connecting An Optional Spool GunIf a MIG gun is connected to theunit, remove it before connectingspool gun.1 Diverter Valve.If sp

OM-1330 Page 22SECTION 5 − OPERATION5-1. Controls1 Voltage Control.Positions 4, 5, and 6 are for 230 voltsac input only.Set Voltage control according

OM-1330 Page 23Notes

OM-1330 Page 245-2. Weld Parameter Chart

OM-1330 Page 25220 493-A

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbo

OM-1330 Page 26SECTION 6 − MAINTENANCE &TROUBLESHOOTING6-1. Routine MaintenanceY Disconnect power before maintaining..Maintain more oftenduring se

OM-1330 Page 276-3. Unit OverloadThermostats TP1 in rectifier SR1 and TP2 in stabilizer Z1 protect the unit from damage due to overheating. If TP1and/

OM-1330 Page 286-6. Aligning Drive Rolls and Wire GuideY Turn Off power.View is from top of drive rollslooking down with pressureassembly open.1 Drive

OM-1330 Page 296-8. Cleaning Or Replacing Gun LinerRef. 802 399-A3/8 inY Disconnect gun from unit.Tools Needed:Lay gun cable out straightbefore instal

OM-1330 Page 306-9. Replacing Switch And/Or Head TubeRef. 800 795-C1 Remove handlelocking nut.2 Remove switch housing. Note: If installing newswitch,

OM-1330 Page 316-10. TroubleshootingWelding Trouble RemedyNo weld output; wire does not feed. Secure power cord plug in receptacle (see Section 4-14).

OM-1330 Page 32SECTION 7 − ELECTRICAL DIAGRAMFigure 7-1. Welding Power Source Circuit Diagram

OM-1330 Page 33220 197-E

OM-1330 Page 34SECTION 8 − MIG WELDING (GMAW) GUIDELINES8-1. Typical MIG Process ConnectionsY Weld current can damageelectronic parts in vehicles.Disc

OM-1330 Page 358-2. Typical MIG Process Control SettingsThese settings are guidelines only. Material and wire type, joint design, fitup,position, shie

TABLE OF CONTENTSSECTION 8 − MIG WELDING (GMAW) GUIDELINES 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-1330 Page 368-3. Holding And Positioning Welding GunWelding wire is energized when gun trigger is pressed. Before lowering helmet andpressing trigg

OM-1330 Page 378-4. Conditions That Affect Weld Bead ShapeWeld bead shape depends on gun angle, direction of travel, electrode extension(stickout), tr

OM-1330 Page 388-5. Gun Movement During WeldingNormally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wide g

OM-1330 Page 398-8. Troubleshooting − Excessive SpatterExcessive Spatter − scattering of molten metal particles thatcool to solid form near weld bead.

OM-1330 Page 408-11. Troubleshooting − Lack Of PenetrationLack Of Penetration − shallowfusion between weld metal andbase metal.Lack of Penetration Goo

OM-1330 Page 418-14. Troubleshooting − Waviness Of BeadWaviness Of Bead − weld metal that is not parallel and does not coverjoint formed by base metal

OM-1330 Page 428-16. Common MIG Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixtures

OM-1330 Page 43Problem RemedyProbable CauseWelding arc not stable.Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace wo

OM-1330 Page 44SECTION 9 − PARTS LIST. Hardware is common andnot available unless listed.Ref. 803 864-E3467891112131415161720212223252627282930102451

OM-1330 Page 45DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Main AssemblyQuantity1 Fig 9-2 BAFFLE,CENTER 1. . . . . . . . . . . . . . . . . . . .

OM-1330 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05Y Warning: Protect yourself and others from injury — read and follow these pr

OM-1330 Page 46803 865-C. Hardware is common andnot available unless listed.18171615131110987654321121419Figure 9-2. Baffle, Center w/Components

OM-1330 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-2. Baffle, Center w/Components (Fig 9-1 Item 1)QuantitySPOOL HUB ASSEMBLY (INCLUDING) 1. . .

OM-1330 Page 48803 866-B. Hardware is common andnot available unless listed.98654321710Figure 9-3. Panel, Rear w/ComponentsDescriptionPartNo.Dia.Mkgs.

OM-1330 Page 49803 867-B. Hardware is common andnot available unless listed.12345681012139117Figure 9-4. Panel, Front w/ComponentsDescriptionPartNo.Di

OM-1330 Page 50DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-5. Wire Drive And Gears (Fig 9-2 Item 18)Quantity2048571 602009 SCREW,.250-20 x 1.25 soc hd

OM-1330 Page 51802 388-B123456713981114151012Figure 9-6. M-10 GunQuantityDescriptionPartNo.ItemNo.Figure 9-6. M-10 Gun (Fig 9-1 Item 19 )1 169 715 NOZ

OM-1330 Page 52DescriptionPartNo.Dia.Mkgs.ItemNo. QuantityOptional Spoolmate Spool Gun Switch207 642186420 SWITCH ASSY 1. . . . . . . . . . . . . . .

Notes

Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2007−01Your distributor also givesyou ...ServiceYou always get the

OM-1330 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914

OM-1330 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-1330 Page 41-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (

OM-1330 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONsom _3/05Y Avertissement : se protéger et protéger les autres contre le risque