Miller M-100 Manuel utilisateur

OM-246 379A 2010−04

Visit our website at

www.MillerWelds.com

Processes

Description

MIG (GMAW) Welding

Semi-Automatic Air-Cooled MIG

(GTAW) Welding Gun

Flux Cored (FCAW) Welding

M-100 Gun

File: MIG (GMAW)

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

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

line catalog or individual specification sheets. To locate your nearest

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

www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. We know you don’t have time to do

it any other way.

That’s why when Niels Miller first started building arc welders in 1929,

he made sure his products offered long-lasting value and superior

quality. Like you, his customers couldn’t afford anything less. Miller

products had to be more than the best they could be. They had to be the

best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

−every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 2009−09

TABLE OF CONTENTS

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

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

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

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

1-4. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 −INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle And Overheating 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Installing Gun 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 −OPERATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Operating The Gun 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 −MAINTENANCE & TROUBLESHOOTING 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing 5. . . . . . . .

4-2. Replacing Switch And/Or Head Tube 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Routine Maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 −PARTS LIST 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-246 379 Page 1

SECTION 1 −SAFETY PRECAUTIONS FOR GMAW

WELDING GUNS −READ BEFORE USING

SR7 (MIG) 2010−03

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! −Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE −Indicates statements not related to personal injury.

.Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

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

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the welding power source Owner’s Manual. Read

and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

DAlways wear dry insulating gloves.

DInsulate yourself from work and ground.

DDo not touch live electrode or electrical parts.

DRepair or replace worn, damaged, or cracked gun or cable insula-

tion.

DTurn off welding power source before changing contact tip or gun

parts.

DKeep all covers and handle securely in place.

DKeep your head out of the fumes.

DVentilate area, or use breathing device.

DRead Material Safety Data Sheets (MSDSs)

and manufacturer’s instructions for material

used.

FUMES AND GASES can be hazardous.

DDo not weld near flammable material.

DDo not weld on closed containers.

DWatch for fire; keep extinguisher nearby.

WELDING can cause fire or explosion.

BUILDUP OF GAS can injure or kill.

DShut off shielding gas supply when not in use.

DAlways ventilate confined spaces or use ap-

proved air-supplied respirator.

MOVING PARTS can injure.

DKeep away from moving parts.

DKeep away from pinch points such as drive

rolls.

DWear welding helmet with correct shade of fil-

ter.

DWear correct eye and body protection.

DCover exposed skin with spatter-resistant

clothing.

ARC RAYS can burn eyes and skin.

HOT PARTS can burn.

DAllow gun to cool before touching.

DDo not touch hot metal.

DProtect hot metal from contact by others.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

DCheck for noise level limits exceeding those

specified by OSHA.

DUse approved ear plugs or ear muffs if noise level is high.

DWarn others nearby about noise hazard.

WELDING WIRE can injure.

DKeep hands and body away from gun tip when

trigger is pressed.

READ INSTRUCTIONS.

DRead and follow all labels and the Owner’s

Manual carefully before installing, operating, or

servicing unit. Read the safety information at

the beginning of the manual and in each

section.

DUse only genuine replacement parts from the manufacturer.

DPerform maintenance and service according to the Owner’s

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

codes.

OM-246 379 Page 2

1-3. Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

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

Health & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known to

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

reproductive harm. Wash hands after use.

1-4. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). Welding current creates an EMF field

around the welding circuit and welding equipment. EMF fields may inter-

fere with some medical implants, e.g. pacemakers. Protective meas-

ures for persons wearing medical implants have to be taken. For ex-

ample, access restrictions for passers−by or individual risk assessment

for welders. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

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

cable cover.

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

to one side and away from the operator.

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

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

welding circuit as possible.

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

possible.

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

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

feeder.

About Implanted Medical Devices:

ImplantedMedical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

OM-246 379 Page 3

SECTION 2 −INSTALLATION

2-1. Specifications

Ref. 243 838-A

Air-Cooled Welding Gun For GMAW And FCAW Welding

Note: Using gasless flux cored wire reduces gun duty cycle.

M-100 Feeds .023 To .045 in. (0.6 To 1.1 mm) Hard Or Flux Cored Wires

Duty Cycle Rating:

100%: 100 A With CO2Shielding Gas

60%: 100 A With Mixed Gases

Weight With 10 ft (3 m) Power Cable: 3.5 lb (1.6 kg)

NOTICE −Exceeding duty cycle

can damage unit and void warranty.

Overheating

A or V

Reduce Duty Cycle

Minutes sduty1 5/95

2-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10

minutes that gun can weld at

rated load without overheating.

Minutes

Definition

Continuous Welding

.023 To .045 in. (0.6 To 1.1 mm)

Hard Or Flux Cored Wires

100% Duty Cycle At 100 Amperes

Using CO2

.023 To .045 in. (0.6 To 1.1 mm) Hard Or Flux Cored Wires

60% Duty Cycle At 100 Amperes

Using Mixed Gases

6 Minutes Welding 4 Minutes Resting

.See Section 2-1. Specifications for amperage rating and duty cycle.

OM-246 379 Page 4

2-3. Installing Gun

243 861-A

1 Gun Securing Knob

2 Gun End

Loosen knob. Insert gun end until it

bottoms against drive assembly.

Tighten knob.

3 Gun Trigger Plug

Insert into receptacle, and tighten

threaded collar.

4 Friction Terminals

Some applications will require

cutting off trigger plug and installing

0.250 female friction terminals onto

end of leads.

See power source manual for

threading procedure.

SECTION 3 −OPERATION

3-1. Operating The Gun

Ref. 243 838-A

1 Trigger Switch

When pressed, energized wire

feeds and shielding gas flows.

OM-246 379 Page 5

SECTION 4 −MAINTENANCE & TROUBLESHOOTING

4-1. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun

Casing

Ref. 243 839-A

!Turn off welding power

source/wire feeder.

1 Nozzle

2 Contact Tip

3 Tip Adapter

.Wire size stamped on tip −check

and match wire size.

Tools Needed:

8 mm, 10 mm

Lay gun cable out

straight before

installing new liner.

Remove nozzle,

contact tip, and

adapter.

Unscrew and

remove liner.

Blow out

gun casing.

Cut off wire and

disconnect gun

from feeder.

5/8 in.

(16 mm)

Liner

Stickout

Install

Liner

.Thread wire according to

welding power source/wire

feeder manual.

Reassemble gun in

reverse order from

taking it apart.

10 mm

Head

Tube

8 mm

OM-246 379 Page 6

4-2. Replacing Switch And/Or Head Tube

Ref. 243 840-A

Tools Needed:

15 mm

Remove screws (5)

and nuts (4). Remove handle halves.

Hand-tighten head tube into cable connector. Place head tube in vice and tighten until

nuts are tight.

Remove from vice. Reposition handle halves, and

install switch housing.

!Turn Off welding power source

/wire feeder and disconnect gun.

Remove switch housing. Install new

switch and connect leads (polarity is

not important). Reassemble in

reverse order. If replacing head tube,

continue to end of figure.

Remove screw on

opposite side.

Secure head

tube in vice.

Loosen jam nut.

Remove from vice

and turn head tube

out by hand.

phillips

Reinstall screws

and nuts.

Reinstall screw on

opposite side.

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