Miller Electric Millermatic 180 Owner's Manual

RProcessesOM-225 311C 2007−05Arc Welding Power Source AndWire FeederDescriptionMIG (GMAW) WeldingFlux Cored (FCAW) WeldingMillermatic 140,140 Auto−Set

OM-225 311 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptib

OM-225 311 Page 72-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenanceRisque D’INCENDIE OU D’EXPLO-SION.D

OM-225 311 Page 82-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Docume

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 9SECTION 3 − SPECIFICATIONS3-1. SpecificationsA. 115 VAC ModelRated

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 103-2. Duty Cycle And OverheatingDuty Cycle is percentage of 10minu

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 113-3. Volt-Ampere CurvesThe volt-ampere curves show theminimum and

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 12SECTION 4 − INSTALLATION4-1. Installing Welding GunRef. 802 982-A

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 134-3. Work Cable Routing Inside UnitRef. 802 982-A1 Work Cable2 Ou

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 144-6. Installing Gas SupplyObtain gas cylinder and chain torunning

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 154-7. Selecting A Location And Connecting Input Power For 115 VAC

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

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 164-8. Selecting A Location And Connecting Input Power For 230 VAC

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 174-9. Electrical Service Guide For 230 VAC Model60 HzSinglePhaseIn

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 184-11. Threading Welding Wire1 Wire Spool2 Welding Wire3 Inlet Wir

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 194-12. Removing MIG Gun From Welding Power SourceOpen Pressure Ass

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 204-13. Installing Optional Spool Gun Switch In Welding Power Sourc

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 214-14. Connecting Spool Gun To Millermatic 140/180804 984-A / Ref.

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 22SECTION 5 − OPERATION5-1. Controls For 115 VAC Model w/Auto-SetE1

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 235-2. Controls For 115 VAC Model1 Wire Speed ControlTurn control c

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 245-3. Controls For 230 VAC Model1 Wire Speed ControlTurn control c

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 25Notes

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

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 265-4. Weld Parameter Chart For 115 VAC Model w/Auto−SetEIMPORTANT:

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 27227 931-HHManual SetupRefer to chart below to select Voltage and

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 285-5. Weld Parameter Chart For 115 VAC Model w/Factory SetNon-Wire

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 29224 940-D3/303.5/452.5/282.5/353/303.5/454.5/355/225/405/305.5/45

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 305-6. Weld Parameter Chart For 115 VAC Model w/Wire Speed Tracking

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 31232 016-A3/303.5/452.5/282.5/353/303.5/454.5/355/225/405/305.5/45

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 325-7. Weld Parameter Chart For 230 VAC Model w/Factory SetNon-Wire

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 33225 229-F225 229−F1.5/20 2/253.5/253/151/152.5/303.5/253.5/203/12

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 345-8. Weld Parameter Chart For 230 VAC Model w/Wire Speed Tracking

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 35232 017-A232 017-A2.5/102/222.5/152.5/153/202.5/282.5/153.5/203.5

TABLE OF CONTENTSSECTION 6 − MAINTENANCE &TROUBLESHOOTING 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 36SECTION 6 − MAINTENANCE &TROUBLESHOOTING6-1. Routine Maintena

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 376-4. Changing Drive Roll Or Wire Inlet Guide1 Inlet Wire GuideRem

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 386-6. Cleaning Or Replacing Gun LinerRef. ST-802 399-A8 mm / 10 mm

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 396-7. Replacing Switch And/Or Head TubeRef. ST-800 795-CTools Need

. A complete Parts List is available on-line at www.MillerWelds.comOM-225 311 Page 406-8. Troubleshooting TableTrouble RemedyNo weld output; wire does

OM-225 311 Page 41Notes

OM-225 311 Page 42SECTION 7 − ELECTRICAL DIAGRAMFigure 7-1. Circuit Diagram

OM-225 311 Page 43234 419-B

OM-225 311 Page 44SECTION 8 − MIG WELDING (GMAW) GUIDELINES8-1. Typical MIG Process ConnectionsY Weld current can damageelectronic parts in vehicles.D

OM-225 311 Page 458-2. Typical MIG Process Control SettingsThese settings are guidelines only. Material and wire type, joint design, fitup,position, s

OM-225 311 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _3/05Y Warning: Protect yourself and others from injury — read and follow these

OM-225 311 Page 468-3. Holding And Positioning Welding GunWelding wire is energized when gun trigger is pressed. Before lowering helmet andpressing tr

OM-225 311 Page 478-4. Conditions That Affect Weld Bead ShapeWeld bead shape depends on gun angle, direction of travel, electrode extension(stickout),

OM-225 311 Page 488-5. Gun Movement During WeldingNormally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wid

OM-225 311 Page 498-8. Troubleshooting − Excessive SpatterExcessive Spatter − scattering of molten metal particles thatcool to solid form near weld be

OM-225 311 Page 508-10. Troubleshooting − Excessive PenetrationGood PenetrationExcessive Penetration − weld metal melting through base metaland hangin

OM-225 311 Page 518-13. Troubleshooting − Burn-ThroughBurn-Through − weld metal melting completely through base metalresulting in holes where no metal

OM-225 311 Page 528-16. Common MIG Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixtu

OM-225 311 Page 53SECTION 9 − PARTS LIST9-1. Recommended Spare PartsQuantityDescriptionPartNo.ItemNo.169 715 NOZZLE, slip type .500 orf flush 1. . .

Notes

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

OM-225 311 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sp

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

OM-225 311 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-225 311 Page 41-5. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Document

OM-225 311 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONsom _3/05Y Avertissement : se protéger et protéger les autres contre le ris