Miller Roughneck C Series Manual de usuario

300, 400, 500, And 600 Ampere MIG Welding Guns

Roughneck C-Series

Processes

Description

MIG (GMAW) Welding

OM-199 706A

August 2001

Visit our website at

www.MillerWelds.com



Flux Cored (FCAW) Arc

Welding

Semi-Automatic, Air-Cooled,

MIG (GMAW) Welding Gun

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.

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 which

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

Milleroffers 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.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

1-2. GMAW Gun Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMF INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

2-3. Gun Connection And Operation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – MAINTENANCE & TROUBLESHOOTING 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Routine Maintenance 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Replacing The Contact Tip 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Installing Or Replacing The Liner 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Replacing Feeder Connector 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Installing Optional Gun Hook 199 662 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Installing Replacement Trigger 199 628 And Optional Locking Trigger 199 661 7. . . . . . . . . .

3-7. Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – PARTS LIST 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-199 706

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 &

Safety Code Section

25249.5 et seq.)

OM-199 706 Page 1

SECTION 1 –SAFETY PRECAUTIONS FOR GMAW

WELDING GUNS –READ BEFORE USING

SR7_7/01

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this

procedure!The possible hazards are shown in the adjoining symbols.

This group of symbols means Warning! Watch Out! Possible ELECTRIC SHOCK and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions to avoid the hazards.

YMarks a special safety message.

.Means NOTE; not safety related.

1-2. GMAW Gun Hazards

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN

AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.

In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The

safety information given below is only a summary of the more complete safety information found in the wire feeder

and welding power source Owner’s Manuals. Read and follow all safety precautions.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY

QUALIFIED PEOPLE.

GMAW WELDING can be hazardous.

ARC RAYS can burn eyes and skin.

1. Wear welding helmet with correct shade of filter.

2. Wear correct eye and body protection.

3. Cover exposed skin with spatter-resistant

clothing.

ELECTRIC SHOCK can kill.

1. Always wear dry insulating gloves.

2. Insulate yourself from work and ground.

3. Do not touch live electrode or electrical parts.

4. Repair or replace worn, damaged, or cracked

gun or cable insulation.

5. Turn off welding power source before changing

contact tip or gun parts.

6. Keep all covers and handle securely in place.

WELDING can cause fire or explosion.

1. Do not weld near flammable material.

2. Do not weld on closed containers.

3. Watch for fire; keep extinguisher nearby.

NOISE can damage hearing; SOME

APPLICATIONS, SUCH AS PULSING,

are noisy.

1. Check for noise level limits exceeding those

specifiedby OSHA.

2. Use approved ear plugs or ear muffs if noise level

is high.

3. Warn others nearby about noise hazard.

HOT SURFACES can burn skin.

1. Allow gun to cool before touching.

2. Do not touch hot metal.

3. Protect hot metal from contact by others.

FUMES AND GASES can be hazardous

to your health.

1. Keep your head out of the fumes.

2. Ventilate area, or use breathing device.

3. ReadMaterial Safety Data Sheets (MSDSs) and

manufacturer’s instructions for material used.

WELDING WIRE can cause puncture

wounds.

1. Keep hands and body away from gun tip when

triggeris pressed.

BUILD UP OF GAS can injure or

kill

1. Shutoff shielding gas supply when not in

use.

2. Always ventilate confined spaces or use

approvedair-supplied respirator.

OM-199 706 Page 2

EMF INFORMATION

The following is a quotation from the General Conclusions Section of

the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields –

Background Paper, OTA-BP-E-53 (Washington, DC: U.S.

GovernmentPrinting Office, May 1989): “. . . there is now a very large

volume of scientific findings based on experiments at the cellular

level and from studies with animals and people which clearly

establishthat low frequency magnetic fields can interact with, and

produce changes in, biological systems. While most of this work is

of very high quality, the results are complex. Current scientific

understandingdoes not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrating, it does not yet

allowus to draw definite conclusions about questions of possible risk

or to offer clear science-based advice on strategies to minimize or

avoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures:

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 the body.

4. Keep welding power source and cables as far away as practical.

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

possible.

About Pacemakers:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your doctor for

completeinformation.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

OM-199 706 Page 3

SECTION 2 –INSTALLATION

2-1. Specifications

Air-CooledGuns For GMAW Welding

Note: Using mixed gases other than CO2reduces duty cycle ratings by 10-50%.

C-30 Gun Feeds .023 To 5/64 in (0.6 To 2.0 mm) Wire

Duty Cycle Rating:

100%: 300 A With CO2Shielding Gas

Weight With 15 Ft (Heaviest) Power Cable: 7.5 lb (3.4 kg)

Maximum Recommended Wire Size –5/64 in

C-40 Gun Feeds .023 To 5/64 in (0.6 To 2.0 mm) Wire

Duty Cycle Rating:

100%: 400 A With CO2Shielding Gas

Weight With 15 Ft (Heaviest) Power Cable: 10.3 lb (4.7 kg)

Maximum Recommended Wire Size –5/64 in

C-50 Gun Feeds .023 To 1/8 in (0.6 To 3.2 mm) Wire

Duty Cycle Rating:

100%: 500 A With CO2Shielding Gas

Weight With 15 Ft (Heaviest) Power Cable: 13 lb (5.9 kg)

Maximum Recommended Wire Size –1/8 in

Ref. ST-800 797-C C-60 Gun Feeds .023 To 1/8 in (0.6 To 3.2 mm) Wire

Duty Cycle Rating:

100%: 600 A With CO2Shielding Gas

Weight With 15 Ft (Heaviest) Power Cable: 14.5 lb (6.6 kg)

Maximum Recommended Wire Size –1/8 in

2-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

withoutoverheating.

Using mixed gases other than CO2

reduces duty cycle ratings 10–50%

depending on gas mixture and

weldingparameters.

YExceeding duty cycle can

damage unit and void

warranty.

100% Duty Cycle At Following Amperes:

C-30 Gun: 300 A With CO2Shielding Gas

C-40 Gun: 400 A With CO2Shielding Gas

C-50 Gun: 500 A With CO2Shielding Gas

C-60 Gun: 600 A With CO2Shielding Gas

Overheating

A or V

Reduce Duty Cycle

Minutes

sduty1 5/95

ContinuousWelding

OM-199 706 Page 4

2-3. Gun Connection And Operation

802 631

1 Gun Securing Knob

2 Gun Block

3 Feeder Connector

Loosenknob. Insert feeder connec-

tor until it is as close as possible to

drive rolls without touching. Tighten

knob.

4 Gun Trigger Plug

5 Gun Trigger Receptacle

Insertplug into receptacle and tight-

en threaded collar.

6 Trigger Switch

Press switch to feed energized wire

and start gas flow.

SECTION 3 –MAINTENANCE & TROUBLESHOOTING

3-1. Routine Maintenance

YDisconnectpower

before maintaining. .Maintain more often

during severe conditions.

Each Spool Of Wire

Blow Out Gun

Casing

Clean

Nozzle

And Check

Contact Tip

3 Months

Replace

DamagedOr

Unreadable

Labels

Clean And

Tighten

Weld

Terminals

Replace Damaged

Gas Hose

Repair Or Replace

Cracked Cables

And Cords

OM-199 706 Page 5

Ref. 802 661

Turn off welding power source/wire

feeder. Cut off wire at contact tip.

1 Nozzle

2 Contact Tip

3 Diffuser

.Correctwire size is stamped on

tip. Be sure to use indicated

wire size.

Tools Needed:

3-2. Replacing The Contact Tip

802 648-A

Turn off welding power source/wire feeder.

Tools Needed:

3-3. Installing Or Replacing The Liner

1 Liner

2 FeederConnector

3 Nozzle

4 Contact Tip

5 Diffuser

6 Fiber Washer

7 Insulator

Lay gun cable out straight. Remove

washer, nozzle, tip, diffuser and in-

sulator. Remove existing liner from

adapter by unscrewing threaded

end of liner and removing liner from

gun cable.

Insert new liner into feeder connec-

tor and feed liner into connector.

Rotate threaded end of liner into

adapterto secure liner in place.

At opposite end of gun cable, cut lin-

er so 7/8 in extends beyond end of

gooseneckas shown. Reinstall in-

sulator, washer, diffuser, tip and

nozzle.

ThreadedEnd

OM-199 706 Page 6

Ref. 802 874 / 802 648

3-4. Replacing Feeder Connector

YTurn off welding power

source and wire feeder.

1 Nozzle

2 Contact Tip

3 Diffuser

4 Fiber Washer

5 Insulator

6 Liner

7 Feeder Connector

Lay gun cable out straight.

Remove nozzle, contact tip, diffus-

er, fiber washer, and insulator. Re-

moveexisting liner from feeder con-

nector by unscrewing threaded end

of liner and removing liner from gun

cable.

8 Screw

Remove screw. Move handle back

to reveal flatted side on handle in-

sert. Using wrenches on handle in-

sert and feeder connector, remove

feeder connector from insert.

Install new feeder connector.

.Gun cable must be straight

when new liner is inserted or

new liner will be cut to incorrect

length, causing wire feed

problems.

Insert new liner into new feeder

connectorand feed liner into feeder

connector. Rotate threaded end of

liner into feeder connector to se-

cure liner in place. Slide handle for-

ward and tighten screw.

At opposite end of gun cable, cut lin-

er so 7/8 in (22 mm) extends be-

yond end of gooseneck as shown.

Reinstallinsulator, fiber washer, dif-

fuser, tip and nozzle.

Threaded End

Flatted Side

7/8 in (22 mm)

Tools Needed:

5/8, 15/16

Old Feeder Connector

New Feeder Connector

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