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Miller Electric Millermatic 90 User Manual

Miller Electric Millermatic 90
40 pages
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cover 8/92 – ST-149 330 PRINTED IN USA
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER ELECTRIC Mfg. Co., P.O. Box
1079, Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
March 1993 Form: OM-1309A
Effective With Serial No. KC192204
CV/DC Welding Power Source/Wire Feeder
For FCAW And GMAW Welding
90 Amperes, 18 Volts At 20% Duty Cycle
Uses 115 Volts AC, Single-Phase Input Power
Overheating, Short-Circuit, And Motor Overload Protection
Usable Range Of 30 To 130 Amperes
Includes Gun, Welding Wire, Gas Valve, And Instructional Video
Millermatic 90 / Millermatic 130
And GA-17C Gun

Table of Contents

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Miller Electric Millermatic 90 Specifications

General IconGeneral
BrandMiller Electric
ModelMillermatic 90
CategoryWelding System
LanguageEnglish

Summary

Introduction and Product Identification

Product Overview

Overview of the Millermatic 90/130 and GA-17C gun.

Miller's True Blue Limited Warranty

Warranty Coverage and Terms

Details of the limited warranty for Miller equipment.

Warranty Exclusions and Limitations

Specifies items and conditions not covered by the warranty.

Arc Welding Safety Precautions

Electric Shock, Fire, and Explosion Hazards

Warnings and precautions against electrical shock, fire, and explosion risks.

Fumes, Noise, and Moving Parts Hazards

Precautions for health risks from fumes, noise, and injury from moving parts.

Magnetic Field Hazard Awareness

Awareness of magnetic fields affecting pacemakers.

General Safety Warnings and Standards

Cylinder, Engine, and Fuel Safety

Safety guidelines for gas cylinders, engines, and fuel handling.

Battery and Coolant Safety

Precautions for handling batteries and hot coolant.

Safety Information Overview

Understanding Safety Symbols and Messages

Explanation of safety alert symbols, signal words, and messages.

Specifications

Welding Power Source Details

Technical specifications for the welding power source.

Welding Gun Specifications

Technical specifications for the GA-17C welding gun.

Performance Curves and Duty Cycle

Volt-ampere curves and duty cycle chart for performance.

Installation Procedures

Included Items and Work Clamp Installation

Lists included items and guides work clamp installation.

Gun Polarity Setup

Instructions for setting gun polarity based on wire type.

Installing the Welding Gun

Steps for connecting the welding gun to the power source.

Location and Input Power Connection

Guidelines for selecting location and connecting input power.

Threading Welding Wire

Procedure for feeding welding wire through the gun.

Installing Gas Supply System

Steps for connecting shielding gas supply.

Operating the Welder

Essential Safety Equipment for Operation

Details on required safety gear for welding operations.

Work Clamp Connection and Usage

Proper connection and placement of the work clamp.

Understanding Controls and Settings

Explanation of welder controls like wire speed and voltage.

Shielding Gas Operation

Proper usage of shielding gas during welding.

Suggested Welding Settings

Recommended settings for various welding applications and materials.

Maintenance and Troubleshooting

Routine Maintenance Schedule

Schedule for regular maintenance tasks to ensure performance.

Overload Protection and Fuse Replacement

Information on overload protection and replacing the motor fuse.

Drive Assembly Cleaning and Repair

Steps for cleaning and repairing the wire drive assembly.

Gun Contact Tube and Liner Maintenance

Procedures for replacing gun contact tubes and cleaning liners.

Wire Spool and Hub Tension Adjustment

How to install wire spools and adjust hub tension.

Troubleshooting Welding Output and Wire Feed

Guides for diagnosing and resolving welding output and wire feed issues.

Electrical Diagrams

Circuit Diagram of Power Source

Schematic diagram of the welding power source circuitry.

Wiring Diagram of Power Source

Detailed wiring diagram showing component connections.

Welding Methods and Troubleshooting

FCAW and GMAW Welding Techniques

Instructions for Flux Cored Arc Welding and Gas Metal Arc Welding.

Factors Affecting Weld Bead Shape

Key factors influencing the shape of the weld bead.

Gun Movement for Weld Quality

Proper gun movement techniques for achieving quality welds.

Troubleshooting Weld Porosity

Causes and corrective actions for weld porosity.

Troubleshooting Spatter and Fusion Issues

Diagnosing and fixing excessive spatter and incomplete fusion.

Troubleshooting Penetration Problems

Identifying and correcting lack of weld penetration.

Troubleshooting Bead Waviness and Distortion

Addressing issues like waviness and distortion in the weld bead.

Parts List

Main Assembly Parts Identification

Identification of parts for the main assembly with diagrams.

Drive Assembly Parts Identification

Identification of parts specific to the wire drive assembly.

GA-17C Gun Parts Identification

Identification of parts for the GA-17C welding gun.

Optional Accessories

Replacement Gun and Spool Adapter

Details on replacement guns and spool adapters.

Cylinder Kits and Operation Videotape

Information on CO2 gas kits and operation videotape.

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