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millermatic 200 SKP-35
Miller millermatic 200 SKP-35 User Manual
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2
Table of Contents
Table of Contents
3
Errata Sheet
5
List of Chart and Tables
7
Safety Rules for Operation of ARC Welding Power Source
9
General Precautions
9
Burn Prevention
9
Toxic Fume Prevention
10
Fire and Explosion Prevention
11
Compressed Gas Equipment
12
Pressure Pegulators
12
Cylinders
12
User Responsibilities
13
Proper Connections
13
Pressurizing Steps
13
Hose
14
ARC Welding
15
Rope Staging Support
15
Protective Clothing
15
Eye and Head Protection
15
Shock Prevention
16
Protection of Nearby Personnel
16
Grounding the Equipment
17
Electrode Holders
17
Connectors
17
Cables
18
Terminals and Other Exposed Parts
18
Electrode
18
Safety Devices
18
Standards Booklet Index
19
Protection for Wearers of Electronic Life Support Devices (Pacemakers)
19
Specifications
21
Overall Dimensions
21
Volt-Ampere Curves
21
Duty Cycle
21
Duty Cycle Chart
22
General Information and Safety
22
Receiving-Handling
22
Description
22
Additional Required Equipment
23
Gas Cylinder (GMAW Only)
23
Flowmeter (GMAW Only)
23
Wire Spool for GMAW Process
23
Installation
24
Optional Equipment
24
Consumable Parts
24
Location
24
Running Gear Installation
25
Optional SKP-35 Panel Installation
26
Shielding Gas Installation
26
Gas Cylinder (Customer Supplied)
26
Regulator/Flowmeter (Custome Supplied)
26
Work Cable Assembly and Installation
27
Weld Polarity Selection
27
For Gas Metal Arc Welding (GMAW) (Electrode Positive/Reverse Polarity)
27
CO2 Installation
27
Drive Rolls and Wire Inlet Installation
28
For Flux Cored Arc Welding (FCAW) (Electrode Negative/Straight Polarity)
28
Drive Roll Installation
28
Electrode Positive/Reverse Polarity Cable Connection Locations
28
GA-20C or Optional GA-40C Welding Gun Connections
29
Inlet Wire Guide Installation
29
Gun Switch Connection
29
Gun/Feeder Connector Installation
29
Installation of Optional Spoolmatic 3 Gun (GMAW Only)
30
Welding Wire Spool Installation
30
Shielding Gas Connections
30
Wire Feed Receptacle Connection
30
Hub Tension Adjustment
31
Electrical Input Connections
31
Matching the Welding Power Source to the Available Input Voltage
31
Wall Receptacle and Power Cable Connections
31
Welding Wire Threading
32
Input
32
Conductor and Fuse Size
32
Operator Controls
33
Power Switch and Pilot Light
33
Voltage Adjustment Switch
34
Wire Speed Adjustment Control
34
Fan-On-Demand
34
Optional Spot Pulse Panel Controls
34
Sequence of Operation
35
Pulse off Time Control
35
Gas Metal ARC Welding (GMAW)-Continuous and Gas Metal ARC Welding-Pulsed ARC (GMAW-P)
35
Suggested Parameters for Pulsed Continuous Welding
36
Gas Metal ARC Welding (GMAW)-Spot (Models with Optional SKP-35 Panel Only)
37
Suggested Welding Parameters
37
Checking Weld Parameters
38
Maintenance and Troubleshooting
39
Flux Cored ARC Welding (FCAW)
39
Shutting down
39
Fan Motor
39
Internal Cleaning
40
Cleaning Drive Rolls
40
Drive Housing Realignment
40
Replacing Hub Assembly
41
Inspecting and Replacing Motor Brushes
41
Hub Assembly
41
Circuit Board and Component Locations
41
Overload Protection
42
Circuit Breaker CB1
42
Circuit Breakers CB2 and CB3
42
SKP-35 Spot Panel Components
42
Thermal Overload Protection
43
Printed Circuit Board Replacement
43
Troubleshooting
43
Motor Control Circuit Board PC1 Replacement
43
Electrical Diagrams
45
Circuit Diagram for Welding Power Source
45
Circuit Diagram for Motor Control Board PC1
46
Circuit Diagram for SKP-35 Panel
46
Circuit Diagram for SKP-35 Panel Circuit Board PC50
47
Wiring Diagram for Welding Power Source
48
Welding Techniques and Troubleshooting
50
Gas Metal ARC Welding (GWAM) - Continuous Seam
50
Gun Position
50
Gas Metal ARC Welding (GMAW)-Pulsed
51
Longitudinal Gun Positions
51
Welding in the Vertical up and Vertical down Position
51
Pulsed Seam
51
Gas Metal ARC Welding (GWAM)-Spot
52
Spot Weld
52
Fender Repair with Spot Nozzle
52
Plug Welds
53
Skip Welding
53
Troubleshooting the Gas Metal ARC Welding Process
53
Porsity
53
Excessive Spatter
54
Incomplete Fusion (Lack of Fusion)
54
Lack of Fusion
54
Excessive Penetration (Burn-Through)
55
Cracks in Weld Metal
55
Waviness of Bead
55
Humping
55
Auto Body Repair Application
56
Pointers for Welding Auto Body Sheet Metal
56
Procedure for Welding Mild Steels
56
Procedures for Welding Door Panels
56
How to Prevent Glass Breakage and Spatter on Windows
57
Procedures for Welding Fenders and Quarter Panels
57
Welding Frames and High Strength (Hss)Steels
57
Hem Flange Removal
57
Parts List
58
Main Assembly
58
Baffle, Air - W/Components
60
Circuit Card
62
Panel, Control - W/Components
63
Wire Drive and Gears
64
Drive Roll and Wire Guide Kits
65
Panel, Front - W/Components
66
Switch, Selector
68
Panel, Rear - W/Components
69
SKP-35 (Spot Panel)
70
10B Running Gear
72
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Miller millermatic 200 SKP-35 Specifications
General
Brand
Miller
Model
millermatic 200 SKP-35
Category
Welding System
Language
English
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