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OM-235 825C 2010−04ProcessesDescriptionMIG (GMAW) WeldingFlux Cored (FCAW) WeldingArc Welding Power Source And WireFeederMillermatic Passport PlusAnd

OM-235 825 Page 6Il reste une TENSION DC NON NÉGLIGEABLE dansles sources de soudage onduleur UNE FOISl’alimentation coupée.D Arrêter les convertisseur

OM-235 825 Page 7LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou même la mort.D Fermer l’alimentation du gaz protecteur en casde non-uti

OM-235 825 Page 8Les PIÈCES MOBILES peuventcauser des blessures.D Ne pas s’approcher des organes mobiles.D Ne pas s’approcher des points de coincement

OM-235 825 Page 92-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Docume

OM-235 825 Page 10

OM-235 825 Page 11SECTION 3 − SPECIFICATIONS3-1. SpecificationsInputVoltageRatedWeldingOutputAmperage RangeMaximumOpen-CircuitVoltage DCAmperes Input

OM-235 825 Page 123-3. Duty Cycle And OverheatingDuty Cycle is percentage of 10minutes that unit can weld at ratedload without overheating.If unit ove

OM-235 825 Page 13SECTION 4 − INSTALLATION4-1. Installing Work Clamp. Tighten connection hardwarewith proper tools. Do not justhand tighten hardware.

OM-235 825 Page 144-3. Process/Polarity TableProcess PolarityCable ConnectionsCable To Gun Cable To WorkGMAW − Solid wire with shield-ing gasDCEP − Re

OM-235 825 Page 154-6. External Shielding Gas Supply1 Shielding Gas ConnectorThe shielding gas connector allowsconnecting an external shieldinggas sup

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-235 825 Page 164-7. 115 VAC Input Power RequirementsConnect input power cord to a 20 A individual branch circuit. If connecting to a circuit protec

OM-235 825 Page 174-9. Electrical Service Guide For 230 VACFailure to follow these electrical service guide recommendations could create an electric s

OM-235 825 Page 184-11. Selecting A Location And Connecting Input Power! Special installation may be requiredwhere gasoline or volatile liquidsare pre

OM-235 825 Page 194-12. Installing 4 in. (102 mm) Wire Spool And Adjusting Hub TensionRotate brake adjust knob untila slight force is needed to turnsp

OM-235 825 Page 204-13. Installing And Threading Welding WireRef. 803 810-EInstalling Wire And AdjustingHub Tension:1 Retaining Nut2 Hub Tension Adjus

OM-235 825 Page 21SECTION 5 − OPERATION5-1. Controls1 Voltage Control Turn control clockwise to increasevoltage.The Voltage Control range fromminimum

OM-235 825 Page 225-2. Weld Parameter Chart.030”(0.8 mm).030”(0.8 mm) Min/10 1.5/20.035”(0.9 mm) .5/10 1.5/15.030”(0.8 mm) Min/10 2/20.035”(0.9 mm) Mi

OM-235 825 Page 23Ref. 235 557-A3/30 4/40 4.5/45 5.5/50 6.5/50 7/50 8/70 9/65 10/803/25 4/30 5/35 6/40 6.5/45 7/45 8.5/55 9/55 10/603/35 3.5/40 4/50 5

OM-235 825 Page 24SECTION 6 − MAINTENANCE &TROUBLESHOOTING6-1. Routine Maintenance! Disconnect powerbefore maintaining.. Maintain more oftenduring

OM-235 825 Page 256-3. Changing Drive Roll Or Wire Inlet Guide1 Inlet Wire GuideRemove guide by pressing onbarbed area or cutting off one endnear hous

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-235 825 Page 266-5. Cleaning Or Replacing Gun LinerRef. ST-802 399-A8 mm / 10 mm! Disconnect gun from unit.Tools Needed:Lay gun cable out straightb

OM-235 825 Page 276-6. Replacing Switch And/Or Head TubeRef. ST-800 795-CTools Needed:19 mmRemove handlelocking nut.Slide handle.Secure headtube in vi

OM-235 825 Page 28SECTION 7 − ELECTRICAL DIAGRAMFigure 7-1. Circuit Diagram

OM-235 825 Page 29235 780-A

OM-235 825 Page 30SECTION 8 − MIG WELDING (GMAW) GUIDELINES8-1. Typical MIG Process ConnectionsY Weld current can damageelectronic parts in vehicles.D

OM-235 825 Page 318-2. Typical MIG Process Control SettingsThese settings are guidelines only. Material and wire type, joint design, fitup,position, s

OM-235 825 Page 328-3. Holding And Positioning Welding GunWelding wire is energized when gun trigger is pressed. Before lowering helmet andpressing tr

OM-235 825 Page 338-4. Conditions That Affect Weld Bead ShapeWeld bead shape depends on gun angle, direction of travel, electrode extension(stickout),

OM-235 825 Page 348-5. Gun Movement During WeldingNormally, a single stringer bead is satisfactory for most narrow groove weld joints;however, for wid

OM-235 825 Page 358-8. Troubleshooting − Excessive SpatterExcessive Spatter − scattering of molten metal particles thatcool to solid form near weld be

TABLE OF CONTENTSSECTION 8 − MIG WELDING (GMAW) GUIDELINES 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-235 825 Page 368-10. Troubleshooting − Excessive PenetrationGood PenetrationExcessive Penetration − weld metal melting through base metaland hangin

OM-235 825 Page 378-13. Troubleshooting − Burn-ThroughBurn-Through − weld metal melting completely through base metalresulting in holes where no metal

OM-235 825 Page 388-16. Common MIG Shielding GasesThis is a general chart for common gases and where they are used. Many different combinations (mixtu

OM-235 825 Page 39SECTION 9 − PARTS LIST9-1. Recommended Spare PartsQuantityDescriptionPartNo.ItemNo.169 715 NOZZLE, slip type .500 orf flush 1. . .

Notes

Notes

Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2010−01Your distributor also givesyou ...ServiceYou always get the

ORIGINAL INSTRUCTIONS − PRINTED IN USA  2010 Miller Electric Mfg. Co. 2010−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer

OM-235 825 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom _2010−037Protect yourself and others from injury — read and follow these precau

OM-235 825 Page 2Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.FUMES AND GASES can be hazardous.D Ke

OM-235 825 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-235 825 Page 41-4. California Proposition 65 WarningsWelding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State

OM-235 825 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONfre_som_2010−037Se protéger et protéger les autres contre le risque de bles