How to connect Miller 10e wirefeeder to HF 110 Amp Welder

[tprothma]

Hi all. I have a Miller CP200 welder which has a Miller MIG 10e wirefeeder connected to it. Will eventually convert the CP200 to single phase (currently 3phase), but wondering how easy it is to connect the 10e wirefeeder to the HF welder 110 Amp.

By the way I have a HF 110 Amp model #94164 and it uses the same board as the HF 151 Mig.

I'm thinking that there is a relay in the 10e that switches on the transformer and that there would be a way to connect it to the HF welder on the output of the relay on the HF board.

Thanks,
Tim

[Joshfromsaltlake]

Doesn't the HF welder come with a wire feeder inside the box? Connecting the power terminals to the miller feeder probably won't do anything except create a tangle of wires. It's not likely to improve your welds at all. Is your idea to take advantage of the solenoid valve on the 10e?

Here's a copy of the owner's manual for the 10e including a wiring diagram on page 6. http://www.millerwelds.com/om/o1230c_mil.pdf The unit runs off of 115 VAC and has a separate wall plug, it seems. Among other things you'd still need to figure out what the relay/contactor voltage on the HF welder is.

I did a little bit of research on your behalf. Converting a CP200 to single phase 220 is complicated to say the least. Don't do it unless you have plenty of knowledge and experience with electronics. See this post.
http://www.practicalmachinist.com/vb...-phase-199832/

I assume that's why you got it for cheap = because not everyone has 3phase power.

[tprothma]

JoshfromSaltLake, the CP200 is just a power source, and I'm considering using the HF welder also as a power source, effectively bypassing the wire feed. Just need help on figuring out the tap points on the HF. It's probably fairly simple for those more experienced with the electrical setup of these welders. I think both power sources (HF and CP200) are cold tip and pulling the trigger does 3 things: opens the gas solenoid, makes the wire feed motor run and switches both legs of the 220V to the transformer (then the tip becomes hot). It's really the details of the switching of the 220V to the transformer that is the key to getting it to work. I'm assuming that it's just switching going on and not requiring feedback to the PWM of the motor.

By the way the CP200 single phase conversion is surprisingly fairly simple. And thanks for the 10e manual... really appreciate it.

Tim

[truckin23]

try this link he explains it simpler http://shdesigns.org/Welding/CP-250/cp-250mods.shtml

[tprothma]

truckin23, thanks for getting back to me. I already finished the single phase conversion about a months ago. I love that site you sent though because he's definitely doing a lot of creative stuff.

The single phase conversion on the Miller CP200 took more time than I expected it to take, but I'm all done and it welds great. Most of the time was spent figuring out the internal wiring, double and triple checking and so forth. Could do it again in less than half the time. The procedure is fairly strait forward, but I found some errors that I relayed back to the author, Dave Kamp. Also I'm now sure I could also use the Miller 10e wirefeeder with the HF welder very easily. Basically I just need a relay to control the 220 to the primary of the transformer of the Harbor Freight. Surplus Center has a nice Deltrol that will do to trick, 30 amp 3 position double throw (only need 2 position single throw) for $6.95. Basically I'd be bypassing the entire HF control board and wiring would be pretty simple. The 10e is able to push .030 Al wire through a 12 foot Tweco torch without breaking a sweat. In practice I'd be using .045 and I'll bet she'll spray quite easily, the CP200 is a monster. The CP200 has a 100% duty cycle at 200A and 60% at 260A and welds as good as any $1500 to $2000 welder being built today at a fraction of the cost... good old fashioned Cu windings like your grand pappy used to use. Just waiting around to get a good deal on the drive rollers. Most of the purists will insist that you use a spool gun with Al, but the old school motors like the one on the 10e used on the bigger welders are really capable, especially for the hobbyist who's not welding all the time.

With the 10e feeder, the HF makes a suitable portable power source and we all know the main weakness of the HF welders and most portable welders is the weak wire feed! Problem solved... well perhaps easier said than done. Just not enough time to do all my projects.

Tim