Miller Electric OM-234 016D Owner's Manual

OM-234 016D 2007−11Spoolmate 100 SeriesVisit our website atwww.MillerWelds.comProcessesDescriptionMIG (GMAW) WeldingWire Feeder Spool GunFile: Wire Fe

OM-234 016 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _2007−047Protect yourself and others from injury — read and follow these precau

OM-234 016 Page 2Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.FUMES AND GASES can be hazardous.D Ke

OM-234 016 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-234 016 Page 41-4. California Proposition 65 WarningsWelding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State

OM-234 016 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONfre_som_2007−047Se protéger et protéger les autres contre le risque de bles

OM-234 016 Page 6Il reste une TENSION DC NON NÉGLIGEABLE dansles sources de soudage onduleur quand on acoupé l’alimentation.D Arrêter les convertisseu

OM-234 016 Page 7LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou même la mort.D Fermer l’alimentation du gaz protecteur en casde non-uti

OM-234 016 Page 8LES FILS DE SOUDAGE peuventprovoquer des blessures.D Ne pas appuyer sur la gâchette avant d’enavoir reçu l’instruction.D Ne pas dirig

OM-234 016 Page 92-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Docume

OM-234 016 Page 10

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

OM-234 016 Page 11SECTION 3 − INSTALLATION3-1. SpecificationsWire Diameter RangeApproximate WireFeed RangeCoolingMethodMaximumSpool SizeWeld CircuitRa

OM-234 016 Page 123-3. Connecting Spool Gun To Millermatic 140/180 ModelsA. Installing Optional Spool Gun Switch In Millermatic 140/180 ModelsRef. 804

OM-234 016 Page 13B. Connecting Spool Gun To Millermatic 140/180804 984-A / Ref. 801 9871 Drive Assembly2 Spool Gun3 Gun Securing Knob4 Gun EndLoosen

OM-234 016 Page 143-4. Connecting Spool Gun To Millermatic Passport Plus805 095-A / Ref. 801 9871 Drive Assembly2 Spool Gun3 Gun Securing Knob4 Gun En

OM-234 016 Page 153-5. Connecting Spool Gun To Renegade 180804 755-B1 Drive Assembly2 Spool Gun3 Gun Securing Knob4 Gun EndLoosen gun securing knob. I

OM-234 016 Page 163-6. Installing Wire Spool And Threading Welding Wire804 985-ATools Needed:1 Thumb Screw2 Spool CoverRemove thumb screw and spoolcov

OM-234 016 Page 17SECTION 4 − OPERATION4-1. Controls For Millermatic 140/180 ModelsA. Spool Gun Operation On Millermatic 140/180 Modelssb5.1* 6/92 − S

OM-234 016 Page 18B. Weld Parameter Chart For Millermatic 140 Model w/Auto−SetEIMPORTANT: Match drive roll groove to diameter of wire being used.

OM-234 016 Page 19227 931-HHManual SetupRefer to chart below to select Voltage and Wire Speed basedon thickness of metal being welded.2. Number on lef

OM-234 016 Page 20C. Weld Parameter Chart For Millermatic 140 Model w/Factory Set Non-Wire Speed Tracking Mode. Color parameter charts can be download

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

OM-234 016 Page 21224 940-E3/403.5/452.5/302.5/353.5/403.5/504.5/354.5/325/505/405/455/354/554/552/302.5/255.5/608/708/605.5/856.5/705.5/556/407/907/7

OM-234 016 Page 22D. Weld Parameter Chart For Millermatic 180 Model w/Factory Set Non-Wire Speed Tracking Mode.030” (0.8 mm).035” (0.9 mm)1. Number on

OM-234 016 Page 23225 229-E225 229−E1.5/20 2/253.5/253/151/152.5/303.5/253.5/203/123.5/605/605.5/354/454/706/1006/407/856/556/656.5/656.5/506.5/7510/7

OM-234 016 Page 24Notes

OM-234 016 Page 254-2. Controls For Millermatic Passport Plus ModelA. Spool Gun Operation On Millermatic Passport Plus Modelsb5.1* 6/92 − S-0621-C / R

OM-234 016 Page 26B. Weld Parameter Chart For Millermatic Passport Plus Model.030”(0.8 mm).030”(0.8 mm) Min/10 1.5/20.035”(0.9 mm) .5/10 1.5/15.030”(0

OM-234 016 Page 27Ref. 235 557-A3/30 4/40 4.5/45 5.5/50 6.5/50 7/50 8/70 9/65 10/803/25 4/30 5/35 6/40 6.5/45 7/45 8.5/55 9/55 10/603/35 3.5/40 4/50 5

OM-234 016 Page 284-3. Controls For Renegade 180 ModelA. Spool Gun Operation On Renegade 180 Modelsb5.1* 6/92 − S-0621-C / Ref. 804 755-B / Ref. 804 9

OM-234 016 Page 29B. Weld Parameters For Renegade 180 ModelSelect Wire Type, Polarity, and ShieldingGasWire SizeMaterial Thickness20 ga 18 ga 16 ga 14

OM-234 016 Page 30SECTION 5 − MAINTENANCE & TROUBLESHOOTING5-1. Routine Maintenance! Disconnect power before maintaining.. Maintain more oftenduri

OM-234 016 Page 315-2. Changing Drive Rolls804 987-ATools Needed:! Turn Off power at weldingpower source first.1 Drive Roll CoverRemove cover.Changing

OM-234 016 Page 325-3. Changing LinerRef. 804 985-ATools Needed:! Turn Off power at weldingpower source first.1 Nozzle2 Contact Tip3 LinerRemove and r

OM-234 016 Page 335-5. GMAW (MIG) Aluminum Welding HintsHere are several hints to help you be more successful with your new aluminum feed system.MIG w

OM-234 016 Page 34S Maintain a 3/4 in. (19 mm) tip-to-work distance, and have the contact tip recessed approximately 1/8 in. inside the nozzle if poss

OM-234 016 Page 35SECTION 6 − ELECTRICAL DIAGRAMSFigure 6-1. Circuit Diagram For Spoolmate186 451

OM-234 016 Page 36Figure 6-2. Circuit Diagram For Millermatic 140/180

OM-234 016 Page 37234 419-B

OM-234 016 Page 38SECTION 7 − PARTS LIST. Hardware is common and notavailable unless listed.804 988-A3226292715282524231817161311104987654213936373835

OM-234 016 Page 39QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Complete Assembly1 PB1 186 416 TRIGGER SWITCH 1. . . . . . . . . . . . . .

Notes

ERRATA SHEET2009−02 OM-234 016DUse above FORM number when ordering extra manuals.After this manual was printed, refinements in equipment design occurr

Notes

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

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

OM-234 016 Page 3CHANGES TO SECTION 4 − OPERATIONAdd Section 4-4. Controls For Millermatic 211 Auto-Sett ModelsAdd Section 4-4A. Spool Gun Operation

OM-234 016 Page 4sb5.1* 6/92 − S-0621-C / Ref. 805 390-A / 804 986-A. Spool Gun/MIG Gun switch onMillermatic 211 Auto-Settmust be in Spool Gun positi

OM-234 016 Page 5. Color parameter charts can be downloaded from www. MillerWelds.comor by ordering from a Miller distributor.

OM-234 016 Page 6239 992-B