Miller Electric M-15 User's Manual
Contents
1. 12 PAGG An GN DIS 146 753 BEZEL front rear 2 nana MO Nang 8 4 whe 2 Mecs she 010 368 CLAMP work 200A 1 at ARR T 026 843 INSULATOR vinyl blk 2 aus AD ccc cece wees 600 325 CABLE weld cop strd No 6 16ft A AN 169 903 M 15 GUN Fig 7 2 1 wi AA Saat aes eet 111 644 BUSHING strain relief 1 jt ote S1 116830 SWITCH rocker DPST 10A 250VAC 1 AO AA NAMEPLATE order by model and serial number 1 e clas KNOB pointer included w ltem 14 1 wt PAB NA 097 922 KNOB pointer 875dia x 250 1 49 TE1 122385 TERMINAL ASSEMBLY consisting of 1 DO pana rires 174504 3x LINK JUMPER sise Laurent aan Waheed ant ced eal ed 2 AR EE TE eos 113 149 CONNECTOR rect 156 14skt 1 Re NE nore i RAR Maning 110 160 CONNECTOR rect 156 6skt 1 bd Sout A en 000 067 TIP contact scr 030 wire x 1 125 1 RE ds 000 068 TIP contact scr 035 wire x 1 125 1 Gia2. 1 sind ss nee 126838 DRIVE ASSEMBLY wire consisting of 1 o ree 090 416 0 00 PIN MNG sumagana Ah ed ore ial ae Bali aad Bats 1 Det 124 817 HOUSING wire drive 444 0 1 od Oriana 151 828 PIN cotter hair 054 x 750 1 MA 112031 LEVER pressure roll e A A A aE A ata E 1 8 EEE 090 443 BEARING ball rdl sgl row 866 OD x 447 width x 315 bore consisting of 1 EE EETA 111 622 SPACER bearing 196 ID x 310 OD x 500 collar 1 Os 010 224 PIN spring CS 187 x 1 000 1 10 fe ents 058 549 GUIDE wire inlet 1 16 1 cdl eens cea 085 242 FASTENER pinned 1 A 085 244 WASHER cupped sil 328 ID x 812 OD x 125 1 Na EC APA PA 090 415 SPRING cprsn 720 OD x 070 wire x 1 250 1 E EA 092 237 KNOB adj tension 1 Mag Lo ARTE eae 119 028 ROLL drive V groove combination 1 PAG pace ees 602 169 SCREW set stl sch 8 32 x 187 cup point 2 PA ee EE 114415 SCREW mach stl phflh 10 24 x 625 1 is
3. 1 ih peo matte 169716 ADAPTER contact tip 2 1 4 170470 RING retaining ene 44e eee 1 Dire 204715 sa O RING a PR nn Pa et tues ME a M AA are 1 Beech 109417 223 WASHERS SHOCK tocino basta ae each ad phan ano a Aao ina 2 Ly Bagan 169718 2 TUBE Nead cerati vai abr 1 8 169 738 NUT locking handle 2 CR 169 719 NUT jam gun end 2 1 ge Qu aot 169 732 sINUT Jam 2n D a ee a da 1 Os 169 720 CONNECTOR cable gun end 1 10 169733 CONNECTOR cable 20 ete teenies 1 bless 169 721 NUT Connector set es r a tenue eee A a we aa dat mans tte 2 o da 172017 M15 UNICABLE CLAMP KIT consisting of 2 Pea ES AAA 169735 CLIP compression 1 de 169742 12 60 TUBE SUDDO KYA ns nan rar nn oe SE ie ae 1 AA 169743 CLAMP inner ent eens 1 16 169 740 025 GLAMP jacket kaa cid ne RATS AW KANG weed AP eres eae 1 AT 169746 CONNECTOR switch lead 2 18 169737 se HAN DEE ick a anida ars 2 ns VQ ie oes 169 741 STRAIN RELIEF cable 2 pdr DR 180 433 CORD trigge
4. 25 6 3 Holding And Positioning Welding Gun 26 6 4 Conditions That Affect Weld Bead Shape 27 6 5 Gun Movement During Welding 28 6 6 Poor Weld Bead Characteristics 28 6 7 Good Weld Bead Characteristics 28 6 8 Troubleshooting Excessive Spatter 29 6 9 Troubleshooting POroSity ario miea de ccc dance eae adie ests eee der Aa ao ares 29 6 10 Troubleshooting Excessive Penetration 30 6 11 Troubleshooting Lack Of Penetration 30 6 12 Troubleshooting Incomplete FUSION 30 6 13 Troubleshooting Burn Through 31 6 14 Troubleshooting Waviness Of Bead 31 6 15 Troubleshooting DISTOMION s genine i NGA POS Bb PU sana es ah Mansel han Wed 31 6 16 Common MIG Shielding Gases 32 SECTION 7 PARTS LIST nan si Ate gs Cae ea Ge dae ee eee ee 34 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage ih A Marks a specia
5. 1 aaa ive NE de Mgt he 141 929 2 HUB Sp00l toc dai hea A deed ae Seed A 1 sacar NO 147 562 BAFRIEE Center 6 see veterana eli as 1 EN OT ere FM 117014 MOTOR fan 230V 50 60 Hz 2600RPM 1 sl Ne GN int a Aa AN a 005 656 BLADE fan 6 000 4wg 30 deg 1 oe OS 2 CR2 108358 CONTACTOR def prp 25A 2P 24V 1 sah Wiha mene SR2 180791 RECTIFIER si 1PH 140A 200PIV 1 res selec Peewee etect 2 147 461 PANEL front 44 444 44222 1 io R1 000 101 RHEOSTAT WW 50W 16 ohm 1 peed ALS beara Be S2 180777 SWITCH rotary 6 pin 1P 600V 1 ne TD Eee RC3 048 282 RECEPTACLE w SOCKETS 1 Ete helen tee er TANG 147 560 PANEL side lower 1 Bana PATA T1 180 786 TRANSFORMER power main 1 sur CC TONI PC1 172543 CIRCUIT CARD consisting of 1 Sod o A F1 073 426 FUSE mintr slo blo 5A 250V 1 20 CR2 080 388 RELAY encl 24VAC 3PDT 10A 120VAC 1 as 173299 CLIP hold down relay 1 pele Amine BARA J
6. 6 Nut Tools Needed PAIE Ref ST 025 190 D 2 5 Installing Gas Supply Obtain gas cylinder and chain to D 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 2 and open valve slightly Gas flow blows dust and dirt from valve Close valve 3 Cylinder SS 4 Regulator Flowmeter 3 Install so face is vertical 5 Gas Hose Connection Fitting has 5 8 18 right hand threads Install gas hose 6 Flow Adjust Typical flow rate is 20 cfh cubic feet Argon Gas per hour Check wire manufactur er s recommended flow rate 7 CO Adapter 8 O Ring Install adapter with O ring between regulator flowmeter and CO cylinder Tools Needed TS 5 8 1 1 8 in CO Gas ssb3 1 12 92 ST 158 697 A OM 1314 Page 11 2 6 Installing Welding Gun And Setting Gun Polarity For Wire Type Gun Opening Gun Trigger Receptacle Gun Securing Nut Drive Assembly 5 Gun End Loosen securing nut Insert gun end through opening until it bottoms against drive assembly Tighten nut 6 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Her 8 ND Close door Follow wire manufacturer s recommendation Solid Steel Or Flux Cored Wires Aluminum Wires FCAW Without Gas GMAW With Gas Straight Polarity DCEN Reverse Polarity DCEP T
7. e Allow cooling period follow rated duty cycle ng Reduce current or reduce duty cycle before G starting to weld again e Donot block or filter airflow to unit ee STATIC ESD can damage PC boards y e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards SS N MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire FIL 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard 249 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 O MOVING PARTS can cause injury e Keep away from moving parts such as fans Ng e Keep all d
8. Voltage controls height and width of weld bead Ref ST 801 865 OM 1314 Page 25 6 3 Holding And Positioning Welding Gun NOTE Ex Welding wire is energized when gun trigger is pressed Before lowering helmet and pressing trigger be sure wire is no more than 1 2 in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 2 3 4 Electrode Extension Stickout Z 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 5 He 0 15 Vd i 90 90 5 QS End View Of Work Angle Side View Of Gun Angle GROOVE WELDS 45 0 15 N x 45 7 N End View Of Work Angle Side View Of Gun Angle FILLET WELDS A OM 1314 Page 26 6 4 Conditions That Affect Weld Bead Shape NOTE es Weld bead shape depends on gun angle direction of travel electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage p 10 Q ARAS ee b 4 10 lj a Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES a Short Normal Long ELECTRODE EXTENSIONS STICKOUT Le Le Iv Short Normal Long FILLET WELD ELECTRODE EXTENSIONS STICKOUT SSeS Slow Normal Fast GUN TRAVEL SPEED S 0634 OM 1314 Page 27 6 5 Gun Movement During Welding NOTE Cr Normally a si
9. 035 in 030 045 in 126 722 IPM 500 IPM 0 6 0 9 mm 0 8 1 1 mm 3 2 18 3 m min 12 7 m min While idling 2 2 Volt Ampere Curves LOAD VOLTS 50 100 150 LOAD AMPS 200 250 Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of other settings fall be tween curves shown va curve1 4 95 SB 180 765 OM 1314 Page 9 2 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating 300 If unit overheats thermostat s 250 opens output stops and cooling fan runs Wait fifteen minutes for 200 unit to cool Reduce amperage or duty cycle before welding 150 A Exceeding duty cycle can fa damage unit or gun and void QC T warranty ul gt lt x 100 O a 75 50 10 15 20 2530 40 50 6070 80 100 DUTY CYCLE 30 Duty Cycle At 130 Amperes DR a 3 Minutes Welding 7 Minutes Resting Overheating pA gt gt Is 6 gt X Reduce Duty Cycle Minutes duty1 4 95 SB 180 844 OM 1314 Page 10 2 4 Installing Work Clamp Insulator Bolt Smaller Hole Work Clamp Tabs Bend tabs around work cable 5 Work Cable From Unit EXP 8 D
10. 2 Y Welding Trouble Remedy No weld output wire does not feed Secure power cord plug in receptacle see Section 2 8 Check and replace power switch if necessary Check fuse F1 and replace if necessary see Section 4 2 Replace building line fuse or reset circuit breaker if open see Section 2 8 Secure gun trigger plug in receptacle or repair leads or replace trigger switch see Section 2 6 and or 4 7 Thermostat TP1 open overheating Allow fan to run the thermostat will close when the unit has cooled see Section 2 3 No weld output wire feeds Connect work clamp to get good metal to metal contact Replace contact tip see Section 4 4 Low weld output Connect unit to proper input voltage or check for low line voltage see Section 2 8 Low high or erratic wire speed Readjust front panel settings see Section 3 1 Change to correct groove in drive roll see Section 2 10 Readjust drive roll pressure see Section 2 10 Replace inlet guide contact tip and or liner if necessary see Sections 4 8 4 4 and or 4 6 Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding Straighten gun cable and or replace damaged parts see Section 4 6 Adjust drive roll pressure See Section 2 10 Readjust hub tension see Section 2 9 Replace contact tip if blocked see Section 4 4
11. 3 Power Switch Ref ST 182 986 B OM 1314 Page 16 SECTION 4 MAINTENANCE amp TROUBLESHOOTING 4 1 Maintenance A Disconnect power E Maintain more often before maintaining during severe conditions 3 Months Vacuum Inside Repair Or Replace Replace A Clean And Damaged Or Cracked A Tighten Unreadable Cables E Ma Labels And Cords onnections Blow Out Or stat maint 2 96 4 2 Fuse F1 Tools Needed CAF 3 8 in If F1 opens wire drive motor shuts down Replace F1 if open Reinstall wrapper and latch door Turn Off unit disconnect in put power Unlatch door and remove wrapper Circuit Board PC1 Fuse F1 See Parts List For Rating Ref ST 801 552 4 3 Short Circuit Shutdown If contact tip is shorted and sticks to workpiece the unit shuts down but fan runs To resume operation release gun trigger turn Off unit and remove contact tip from workpiece Check contact tip and replace if damaged Turn On unit to continue operation OM 1314 Page 17 4 4 Replacing Gun Contact Tip ES e A Turn Off power before Pa ES replacing contact tip 1 Nozzle 2 Contact Tip Cut off welding wire at contact tip Remove nozzle Remove contact tip and install new contact tip Reinstall nozzle Tools Needed EF OC ST 149 32
12. 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 e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e 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 e 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 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shi
13. Clean or replace wire inlet guide or liner if dirty or plugged see Section 4 8 and Section 4 6 Replace drive roll if worn or slipping see Section 2 10 Secure gun trigger plug in receptacle or repair leads or replace trigger switch see Section 2 6 and or 4 7 Check and clear any restrictions at drive assembly and liner see Section 4 8 and Section 4 6 Have nearest Factory Authorized Service Agent check drive motor Check relay CR1 and replace if necessary OM 1314 Page 22 SECTION 5 ELECTRICAL DIAGRAM lt RC2 2 bak ee ee A EH resa gt z RC3 2 J ASAS Rc3 1 lt lt RC2 4 PCI RC3 3 A RC1 PLG1 RC2 PLG2 Te Pan ae ae N a Di ODO 5 O O O O O D O D D 14 14 K Y Y Y Y Y Y Y Y Y Y K VV y V V si ovo o o0 la z 4 AK ee CR _Z g HAT 2 NJ POS D 2 24V 9 ke 15 s MG 1 lak WH OC o2 BEG TRANS 5 2 4 A 3 5 PE si 4 5 ZI TT 5 27 i ci CR2 PLCS WHT 2 17 S2 6 2 N NEG lt RIBBED i ne a e WORK TE csi AK EU 4 7 TORCH an END POS E G WORK TORCH a SB 180 784 B RC4 Figure 5 1 Circuit Diagram OM 1314 Page 23 SECTION 6 MIG WELDING GMAW GUIDELINES 6 1 Typical MIG Process Connections A Weld current can damage electronic parts in ve
14. TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE W
15. d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES Se peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 1314 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PIECES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAM
16. des yea ces Dat 166 575 WRENCH hex 078 1 SC 121 448 C To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1314 Page 38 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also 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 Miller The Power of Blue Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY A
17. et seq TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 121 Symbol Usage crea ANA kramade ALAALA aes tata da heeled AANGAL 1 1 2 Are Welding Hazards 1 23 ete Pie AS ee PYAR cede a de dus ee ee 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 Principal Safety Standards eee e eee 3 1 5 EMElnformation pt asane r A nr a A A Ed ce NA 4 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5 1 1 Signification des symboles 5 1 2 Dangers relatifs au soudage l arc 5 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement etla maintenance tecate tee done nie a Lots rang AY 7 1 4 Principales normes de s curit 8 1 5 Information sur les champs lectromagn tiques 8 SECTION 2 INSTALLATION 222 22022 KE KA BK A a E A 9 21 Specification NAG NANG ANNA NA AN ANA NAA Se Sees 9 2 2 Volt Ampere Curves 9 2 3 Duty Cycle And Overheating 000 ccc tenet eens 10 2 4 Installing Work Clamp 00 ete nee teen eens 11 2 52 Installing Gas Supply e eden oy eee E obs 11 2 6 Installing Welding Gun And Setting G
18. 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 e 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 e 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 1314 Page 1 ARC RAYS can burn eyes and skin 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 e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion
19. nn Y i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT a e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage e Ne pas obstruer les passages d air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s y E e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir re u l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage sz 5 a DES ORGANES MOBILES peuvent provoquer des blessures S e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute frequence peut provoquer des interf rences avec les
20. or shielding the work area 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 1314 Page 3 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 committees 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 f
21. out by hand Do not disturb cable connection between cable connector and connector nut 7 Install both existing shock washers 8 Place head tube in vice and tighten to new head tube and hand tighten to within 1 8 in 3 2 mm spacing be head tube into connector cable tween connector cable and body ME ad 9 Remove from vice Reposition handle and install switch housing Secure with handle locking nut Tools Needed Ss 22 3 4 in LI Ref ST 800 795 A OM 1314 Page 20 4 8 Cleaning Or Repairing Drive Assembly A Turn Off power before HA cleaning or repairing drive assembly 1 Wire Spool 2 Nozzle Cut welding wire off at nozzle Retract wire onto spool and secure 3 Pressure Roll Arm Cotter Pin Pin Screw Bearing Remove bearing Install new bear ing and secure with screw Reinstall arm onto pin and secure with cotter NO BR pin 8 Setscrew 9 Drive Roll Remove drive roll Push drive roll onto shaft with desired groove in Turn drive roll so one setscrew faces flat side of shaft and tighten both setscrews 10 Wire Inlet 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 Close door Tools Needed IB 7 ean E E O Ref ST 150 093 A ST 149 266 B OM 1314 Page 21 4 9 Troubleshooting HN J NN ANO
22. quipements de ra dio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Si le FCC signale des interf rences arr ter imm diatement l appa reil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lectronique sensible e Veiller a ce que ce poste de soudage soit pose et mis a l
23. work surface before welding Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Dirty welding wire Use clean dry welding wire Eliminate pickup of oil or lubricant on welding wire from feeder or liner 6 9 Troubleshooting Porosity a o Porosity small cavities or holes resulting from gas pockets in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clean dry welding wire Eliminate pick up of oil or lubricant on welding wire from feeder or liner Workpiece dirty Remove all grease oil moisture rust paint coatings and dirt from work surface before welding Use a more highly deoxidizing welding wire contact supplier Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle 6 10 Troubleshooting Excessive Penetration Y Excessive Penetration weld metal mel
24. 5 0 E70S 6 Voltage Tap 6 5 4 3 3 2 1 CO 030 3 20 cfh Wire Speed 60 45 40 35 30 25 20 Voltage Tap 6 5 4 3 2 2 2 035 Wire Speed 30 20 20 20 20 15 5 Voltage Tap 6 5 4 3 3 2 2 1 023 Wire Speed 100 90 75 60 50 35 20 10 E70S 6 75 Argon Voltage Tap 6 5 4 3 3 2 1 1 030 25 CO2 Wire Speed 70 60 50 40 30 20 10 0 20 cfh Voltage Tap 6 5 5 4 3 2 2 035 Wire Speed 50 45 40 30 25 25 10 Voltage Tap 6 6 5 4 3 2 2 030 E71T GS Wire Speed 50 45 30 20 20 10 10 Flux Core Voltage Tap 6 6 5 4 3 035 Wire Speed 40 40 30 20 20 Voltage Tap 5 4 4 3 3 3 3 ER 308 023 3 Stainless Steel Wire Speed 100 90 75 60 50 40 25 Tri Mix Voltage T 6 5 4 3 3 20 cfh 030 a AR Wire Speed 75 70 60 50 40 tuned during welding SECTION 3 OPERATION 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 S 181 186 3 1 Controls WIRE SPEED 1 A ig PONDER LOAD Ni H 5 KA VOLTAGE on 40 cam 50 30 70 1 20 OF 10 90 100 OFF 0 Ke woy ee e i 1 Wire Speed Control Use control to select a wire feed speed As Voltage switch setting in creases wire speed range also in creases 2 Voltage Switch The higher the selected number the thicker the material that can be welded Do not switch while welding
25. 6 B 4 5 Unicable Repair To repair or replace unicable order Unicable Clamp Kit part number 172 017 Kit includes all required instructions clamps inner support tube compression clip switch leads and connectors OM 1314 Page 18 4 6 Cleaning Or Replacing Gun Liner A Disconnect gun from unit a l iy We Q LU W C CR Head Tube Y Remove nozzle contact tip adapter and wire outlet guide UIT 7 3 8 in Lay gun cable out straight before installing new liner Blow out gun casing Tools Needed TT 2 3 8 in Wire Outlet Guide 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 Ref ST 800 797 A OM 1314 Page 19 4 7 Replacing Switch And Or Head Tube ry E A Disconnect gun from unit 3 Slide handle 1 Remove handle 2 Remove switch housing Note If installing new locking nut 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 4 Secure head 5 Remove shock washers 6 Loosen jam nut Remove tube in vice from front and rear of from vice and turn head head tube tube
26. ITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 7 00 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment sovice and Mapai Miller Electric Mfg Co Replacement Parts An Illinois Tool Works Company 1635 West Spencer
27. Miller The Power of Blue OM 1314 180 846A February 1997 Processes MIG GMAW Welding Flux Cored FCAW Welding Description e A Arc Welding Power Source And Wire er Millermatic Challenger And M 15 Gun O Visit our website at www MillerWelds com o OWNER S MANUAL From Miller to You 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 T RU E BI Il E tradition They re just as committed to providing equipment and service oR WARRANTY YI that meets the high standards of quality and value established in 1929 Working as hard as you do This Owner s Manual is designed to help you get the most out of your every power source from Miller is backed by the most Miller products Please take time to read the Safety precautions They will hassle free warranty in the help you protect yourself against potential hazards on the worksite We ve business made installation and operation quick and easy With Miller you c
28. ND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer x x 3 1 Year Parts and Labor DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Uni
29. NG BAG NAP NALITO de 087 299 TIP contact scr 023 wire x 1 125 1 a be NAT ERA 166575 WRENCH hex 078 across 1 a AE 135615 BUSHING nylon 390 ID x 750 OD x 7501g 2 ts 183312 ADAPTER RING wire spool 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1314 Page 35 Hardware is common and not available unless listed 9 10 11 13 14 25 27 15 12 26 Includes Item 17 ST 801 140 Figure 7 2 M 15 Gun OM 1314 Page 36 Item Par No No Description Quantity 169 589 Figure 7 2 M 15 Gun Fig 7 1 Item 43 Las 169 715 NOZZLE slip type 500 orf flush 1 1 0176237 NOZZLE spotflat 1 1 176239 NOZZLE spot inside corner 1 1 176241 NOZZLE spot outside corner 1 2 087 299 TIP contact scr 023 wire x 1 125 1 Das 000 067 TIP contact scr 030 wire x 1 125 1 2 000 068 TIP contact scr 035 wire x 1 125
30. PS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des operations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ou e Le bruit des processus et des quipements peut affecter louie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seuleme
31. Street Training Schools Videos Books Appleton WI 54914 USA ae International Headquarters USA Technical Manuals Servicing Information USA Phone 920 735 4505 Auto Attended and Parts USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 Circuit Diag rams European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Welding Process Handbooks www MillerWelds com Contact the Delivering Carrier for File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department Miller The Power of Blue PRINTED IN USA 2000 Miller Electric Mfg Co 6 00
32. T TC 15 16 in When a slight force is needed to turn spool tension is set S 0499 OM 1314 Page 14 2 10 Installing Drive Roll And Threading Welding Wire EP 1 Install drive roll For Flux Cored Wire 2 Open pressure assembly 4 Push wire thru guides into gun continue to hold wire 5 Close and tighten pressure assembly and let go of wire 7 Turn power On 9 Reinstall contact tip and nozzle Tools Needed Se cs Il NI mes Bi Install drive roll onto shaft with de sired groove in and one set screw facing flat side of shaft Tighten both set screws For Solid Wire 3 Pull and hold wire cut off end of gun 10 Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire leave 1 4 1 2 in 6 13 mm Close and latch door Ref ST 149 266 B Ref ST 149 326 B Ref 150 093 A Ref 180 968 S 0627 A WOOD OM 1314 Page 15 2 11 Weld Parameters Wire Type Wire Material Thickness Shielding Gas Diameter ba tah 1 4in 3 16in 1 8 in And Flow Rate inch 6 4mm 4 8mm 3 2 mm 14 ga 16 ga 18 ga 20 ga 22 ga Voltage Tap 5 4 3 3 2 2 1 023 Wire Speed 70 60 50 30 20
33. a terre conform ment a ce mode d emploi e En cas dinterferences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 1314 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Sui
34. ait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 1314 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppose de l op rateur 3 Ne pas courber pas et ne pas entourer pas les cables autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Relier la pince de masse le plus pres possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 INSTALLATION 2 1 Specifications Amperes Input at s Maximum Rated Welding Amperage irei Rated Load Out Overall Output Range apan GAN put 230 V 60 Hz KVA Sad Weight Dimensions 9 Single Phase Length 17 in 432 mm 130 A 20 5 Volts 40 170 33 20 5 4 7 4 95 Ib Width 10 in DC 30 Duty Cycle 0 27 05 04 43 1 kg 254 mm Height 15 1 2 in 394 mm Solid Flux Cored Calculated Wire Stainless Aluminum Speed Range At Max Wire Feed Speed While Welding Wire Type No Load And Dia 023
35. an count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a REGISTERED QUALITY SYSTEM Troubleshooting section that will help you Miller is the first welding figure out what the problem is The parts list equipment manufacturer in ine US A lo bo ag sato will then help you to decide which exact part the ISO 9001 Quality System you may need to fix the problem Warranty and alaga service information for your particular model are also provided 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 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 catalog 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 Miller The Power of Blue 4 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health 8 Safety Code Section 25249 5
36. ationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance A FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e 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 e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit a gag OVERUSE can cause OVERHEATING
37. c ble de retour som nd fre 5 97 a PAL Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour viter tout danger e Ne pas toucher l lectrode quand on est en contact avec la piece la terre ou une lectrode provenant d une autre machine e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le cable de retour de fagon a obtenir un bon contact m tal m tal avec la pi ce a souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces D LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz L
38. es normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticuli rement les enfants Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entra nement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact phy sique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique acourant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e Si l utilisation d une source lectrique acourant lec
39. eur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e A l int rieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimenta tion d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du fabricant concernant les m taux les consomma bles les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxy g ne provoquant des blessures ou des accidents mortels S assu rer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en presence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n cessaire en por
40. ha 134 201 STAND OFF support PC card 4 J Sea Oe ete ha La antes 147 563 WRAPPER 0 ccc ccc ce eee en ent nen en eens 1 PC Gan PP hh ot aoa 089 899 LATCH SIIde USA sieti tarre Pahoa ohh ek dete he dat banni 1 NAA 134327 LABEL warning general precautionary 1 KAI AR A od 126 415 CLAMP saddle 1 A ete amp 126 416 HANDLE molded plastic 1 ee ES E 111 443 BUSHING strain relief 1 28 PLG1 152118 CORD SET 250V 6 50P 12GA 3 c 1 na BI a ines BNG Ka 605 227 NUT 750 14 knurled 1 A 147 462 2 PANEL TO ar aia BNG LG PRA AG iaa 1 al ts GS1 128751 VALVE 230VAC 2 way 1 Ai OE OR eek R2 3 181649 RESISTOR WW fxd 40W 25 ohm 2 Oe VR1 090288 VARISTOR w TERMINALS 1 eo eet C1 162245 CAPACITOR elctlt 140000uf 1 PCRS Baal Aa BAN LAG 022 160 CLAMP capacitor 3 000dia 1 AO Di ZA xe 180793 22 STABILIZER La tE ire ted ne Ie dS eee 1 As 14 5660 BASE ma AA AA e ae HA 1 pan BB Ka etka eee 147 548 NUT speed push on type
41. hicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Regulator Flowmeter Wire Feeder Power Source Ji Gun Shielding Gas 5 _ o y ele Gas S Workpiece CT CT Work Clamp light mig 5 967 ST 801 909 OM 1314 Page 24 6 2 Typical MIG Process Control Settings NOTE Eg These settings are guidelines only Material and wire type joint design fitup position shielding gas etc affect settings Test welds to be sure they comply to specifications Material thickness determines weld parameters Us 1 8 or i 125 in Convert Material Thickness to 4 Amperage A 1 001 in 1 ampere 125in 125A y Wire Size Amperage Range 023 in nr Select Wire Size 030 in 40 145A 035 in 50 180 A Wire Wire Speed Select Wire Speed Size Recommendation Approx Amperage 023 in 3 5 in per ampere 3 5 x 125 A 437 ipm 125 A based on 1 8 in 030 in 2 in per ampere 2 x 125 A 250 ipm material thickness 035 in 1 6 in per ampere 1 6 x 125 A 200 ipm ipm inch per minuto y Low voltage wire stubs into work High voltage arc is unstable spatter Select Voltage Set voltage midway between high low voltage Wire speed amperage controls weld pe netration wire speed burn off rate
42. ields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 1314 Page 4 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 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles A ldentifie un message de s curit particulier Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 4 Veuillez lire et respecter toutes c
43. l safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards A 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 A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away Ha 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 e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical co
44. nge and or adjust wire feed speed Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Use correct gun angle of 0 to 15 degrees 6 13 Troubleshooting Burn Through Burn Through weld metal melting completely through base metal resulting in holes where no metal remains S 0640 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase and or maintain steady travel speed OM 1314 Page 30 6 14 Troubleshooting Waviness Of Bead ae Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal LA hd S 0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Unsteady hand Support hand on solid surface or use two hands 6 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces i Base metal moves in the direction of the weld bead S 0642 Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in position Make tack welds along joint before starting welding operation Selec
45. ngle stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads works better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side To Side 1 2 Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode 3 EE DM S 0054 A 6 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration a BB ON S 0053 A 6 7 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal S 0052 B OM 1314 Page 28 6 8 Troubleshooting Excessive Spatter o NLA Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead S 0636 Possible Causes Corrective Actions Wire feed speed too high Select lower wire feed speed Voltage too high Select lower voltage range Electrode extension stickout too long Use shorter electrode extension stickout Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from
46. nt des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance gi Risque D INCENDIE OU fa D EXPLOSION e Ne pas placer l appareil sur au dessus ou a proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil
47. ntact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e 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 e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e 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 e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som nd 5 97 e A T si 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 e lf earth grounding of the workpiece is required ground it directl
48. ools Needed LT 5 16in ST 149 328 B Ref ST 159 270 OM 1314 Page 12 2 7 Electrical Service Guide Input Voltage 230 Input Amperes At Rated Output 20 5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 25 Min Input Conductor Size In AWG Kemil 14 Max Recommended Input Conductor Length In Feet Meters 64 19 Min Grounding Conductor Size In AWG Kemil 14 Reference 1996 National Electrical Code NEC S 0092 J 2 8 Selecting A Location And Connecting Input Power 18 in 457 mm of space for airflow A Always connect grounding conductor first GND PE A Do not move or operate unit where it could tip 1 Rating Label Supply correct input power 2 Plug 3 Receptacle Connect plug to receptacle 4 Line Disconnect Device See Section 2 7 A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 230 VAC 1 v ssb2 2 1 94 ST 801 504 OM 1314 Page 13 2 9 Installing Wire Spool And Adjusting Hub Tension Es Standard Wire Spool Standard Wire Reel Part No 183 312 eS 3 1 Lb Wire Spool Part No 135 615 Tools Needed EF gt
49. oors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e If notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained 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 e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters
50. r assembly consisting of 1 21 180 551 BLOCK terminal rear inc dec 1 HOS ms 180427 cr GORD MI ateos 1 DS ones 173 521 CONNECTOR feeder consisting of 1 24 079974 O RING 500 ID x 103CS rbr 2 25 6172257 KIT liner monocoil 023 025 wire x 15ft consisting of 1 lan IN 172 258 KIT liner monocoil 030 035 wire x 15ft consisting of 1 26 hen 079975 trer O RING 187 ID 1 08CS Tbr a aka eee dant bee RG la 1 SMALL tats 109 723 GUIDE OUCH Ha aa kaa B NT PIGA ag aa a Wala ed gett ne Gale ANS 1 28 169739 SWITCH trigger 4422200 1 OPTIONAL To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 1314 Page 37 E Hardware is common and not available unless listed 3 ncludes Items 6 thru 14 Figure 7 3 Drive Assembly Wire Item Dia Part No Mkgs No Description Quantity Figure 7 3 Drive Assembly Wire Fig 7 1 Item 1 s1 3 MOT T73 446 5 MOTOR Li eal st ee ac A eee PDA a aa 1 PADI ite a wenn 129893 INSULATOR housing drive
51. rt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding eus FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 1314 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away 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 e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged 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 Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a st
52. s chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit la o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le cable sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques
53. t lower voltage range and or reduce wire feed speed Increase travel speed Weld in small segments and allow cooling between welds OM 1314 Page 31 6 16 Common MIG Shielding Gases This is a general chart for common gases and where they are used Many different combinations mixtures of shielding gases have been developed over the years The most commonly used shielding gases are listed in the following table Application Sas Spray Arc Steel Short Circuiting Steel Pade Ne Argon All Positions Argon 25 CO Flat amp Horizontal Fillet All Positions All Positions CO Flat amp Horizontal Fillet All Positions Tri Mix3 All Positions 1 Globular Transfer 2 Single Pass Welding Only 3 90 HE 7 1 2 AR 2 1 2 CO2 OM 1314 Page 32 Notes OM 1314 Page 33 SECTION 7 PARTS LIST Figure 7 1 Main Assembly OM 1314 Page 34 Item Dia Part No Mkgs No Description Quantity Figure 7 1 Main Assembly Belly AA 131 315 DRIVE ASSEMBLY wire Fig 7 3 1 A tet cok ea NS sees oka Ry 010 909 NWT 3375216 24 a a a Es 1 EE E EAEE 010910 WASHER flat 406 ID x 0 81 OD 2 TE EE E 073 355 SPRING cprsn 625 OD x 0 93 W 1 ES EE aaa 111 998 PIN cotter hair 120dia x 2 8
54. tant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 1314 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI 249 1 et Z87 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder larc e Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds N F LE SOUDAGE peut provoquer un PS incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les des pi ces chaudes et des quipement
55. te 501 Arlington VA 22202 Regles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les cables de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci a propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re search Council a conclu Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques a haute fr quence repr sente un risque a la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent a tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous ser
56. ting through base metal and hanging underneath weld Excessive Penetration Good Penetration S 0639 Possible Causes Corrective Actions Excessive heat input Select lower voltage range and reduce wire feed speed Increase travel speed OM 1314 Page 29 6 11 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration S 0638 Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics Improper weld technique Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration Keep arc on leading edge of weld puddle Be sure welding wire extends not more than 1 2 in 13 mm beyond nozzle Insufficient heat input Select higher wire feed speed and or select higher voltage range Reduce travel speed 6 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead i EE S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage ra
57. trique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le
58. ts Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS
59. un Polarity For Wire Type 12 2 7 Electrical S rvice Guides aviacion 13 2 8 Selecting A Location And Connecting Input Power 13 2 9 Installing Wire Spool And Adjusting Hub Tension 14 2 10 Installing Drive Roll And Threading Welding Wire 15 2 11 Weld Parameters is apa ALINA kak A ee N had 16 SECTION 3 OPERATION 22202 cede a NONA NG 16 O se ani Gs O AN 16 SECTION 4 MAINTENANCE 8 TROUBLESHOOTING 17 4 1 Maintenance 2283 Nka ENNA a teen ALA oA e Ae 17 4 2 Fuse FA Line r animation te nent Ne ph at hae 17 4 3 Short Circuit Shutdown sta ca E Une area 17 4 4 Replacing Gun Contact Tip 18 45 Unicabl R pair cosa AA 18 4 6 Cleaning Or Replacing Gun Liner 2 19 4 7 Replacing Switch And Or Head Tube 20 4 8 Cleaning Or Repairing Drive Assembly 21 4 9 Troubleshooting xo erates caine a ANAND NGA PNTA 22 SECTION 5 ELECTRICAL DIAGRAM 0 000 e cece eect eee eee eee eeee 23 SECTION 6 MIG WELDING GMAW GUIDELINES 44 444ssssesuusss 24 6 1 Typical MIG Process Connections 24 6 2 Typical MIG Process Control Settings
60. y with a separate cable do not use work clamp or work cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e 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 e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if
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