Issued Jan. 2015 • Index No. M/1.

76

Spoolmatic Pro ® MIG Welding

Spool Gun

Air-Cooled Pistol-Grip Spool Gun

Heavy Industrial Applications Processes Wire Types Rated Output
Emergency Vehicles Shipbuilding MIG (GMAW) Aluminum 200 A at 100% Duty Cycle
Quick Recreational Vehicles Tool Boxes Pulsed MIG Steel
Net Weight
Trucks and Trailers Railcars (GMAW-P)
Specs Boat/Yacht Building Fabrication with pulsing
Gun only: 3.1 lb. (1.4 kg)
Sign Manufacturers Repair 15-ft. Gun with Cable: 10.4 lb. (4.7 kg)
power source 30-ft. Gun with Cable: 15.7 lb. (7.1 kg)

A complete system consists of the following:

Spoolmatic Pro spool gun (Includes .035–1/16 in. knurled
The industry’s drive roll and two FasTip™ contact tips —.035 in. and 3/64 in.)
most reliable WC-24 or WC-115 weld control (Required unless using a
machine that allows direct hookup.)
line of aluminum Recommended Miller 14-pin power source OR select
welding guns. Millermatics (See page 6.)

The Spoolmatic Pro spool gun is available in 15- or 30-foot (4.6 or 9 m)

cable lengths and features a built-in gas valve, rotatable canister, and
isolated common knurled drive roll.

Aluminum-series-specific
tension settings ensure
smooth wire feeding
performance with 4000 or
5000 series aluminum wires.

Easy access to drive assembly and removable

toolless head tube reduces service time by
allowing a simple means of changing drive rolls
and head tube or performing routine maintenance
without disassembly of gun.
Direct-connect (no adapters needed),
Improved motor and drive design for better easy-to-rotate, self-seating head tube options
feedability and arc consistency while helping in several different lengths and bend configurations
reduce downtime and maintenance costs (see page 4).
associated with complex drive systems.

Guns are warranted for 1 year, parts and labor.

Miller Electric Mfg. Co. Equipment Sales US and Canada MillerWelds.com

An ITW Company Phone: 866-931-9730
1635 West Spencer Street FAX: 800-637-2315
P.O. Box 1079 International Phone: 920-735-4554
Appleton, WI 54912-1079 USA International FAX: 920-735-4125
 Specifications (Subject to change without notice.)
Welding Current Maximum Spool
Rating Wire Feed Speed Wire Diameter Capacity Size Capacity Gun Dimensions Net Weight
200 A at 70 – 900 IPM Aluminum*: 4 in. (102 mm) H: 10.75 in. (273 mm) Gun only: 3.1 lb. (1.4 kg)
100% duty cycle (1.8 – 23 m/min.) .030 – 1/16 in. (0.8 – 1.6 mm) W: 2.5 in. (64 mm) 15-ft. gun with cable: 10.4 lb. (4.7 kg)
dependent on control box Hard Wire: L: 15.375 in. (390 mm) 30-ft. gun with cable: 15.7 lb. (7.1 kg)
or Millermatic used .030 – .045 in. (0.8 – 1.1 mm)
*Wire kit #230 708 required to run 1/16-inch (1.6 mm) wire.

Standard Replacement Consumables (Order from Miller Service Parts.)

Aluminum Wire Size FasTip Contact Tip (Qty. 25) Drive Rolls Idler Rolls Head Tube Liner 4 in. (102 mm)
.030 in. (0.8 mm) #206 186 .041-in. ID #227 434 #227 439 M1272
.035 in. (0.9 mm) #206 187 .047-in. ID #227 434 #227 439 M1272
.040 in. (1.0 mm) #206 188 .053-in. ID #227 434 #227 439 M1272
3/64 in. (1.2 mm) #206 189 .061-in. ID #227 434 #227 439 M1273
1/16 in. (1.6 mm) #206 191 .071-in. ID #227 434 #230 710 M1273

Standard Consumables–FasTip Series (Order from Miller Service Parts.)

™

Gas Diffusers FasTip Contact Tips Nozzles

(25 per package)
Screw-On Brass
#199 610 1/2-in. orifice, tapered
#199 611 3/4-in. orifice, straight
#199 612 3/4-in. orifice, straight HD
#229 670 Standard Heavy-Duty (Aluminum Wire) #199 613 5/8-in. orifice, tapered
1/8-inch tip recess for heavy-duty FasTip #206 186 .030 in. (0.8 mm) #199 614 5/8-in. orifice, tapered HD
contact tips. #206 187 .035 in. (0.9 mm)
Screw-On Copper
#230 678 #206 188 .040 in. (1.0 mm)
#199 615 1/2-in. orifice, tapered
1/4-inch tip recess for heavy-duty FasTip #206 189 3/64 in. (1.2 mm)
#199 616 3/4-in. orifice, straight
contact tips. #206 191 1/16 in. (1.6 mm)
#199 617 3/4-in. orifice, straight HD
#230 679 Tapered (Aluminum Wire) #198 855 5/8-in. orifice, tapered
Flush tip for heavy-duty FasTip contact tips. #209 026 .030 in. (0.8 mm) #199 618 5/8-in. orifice, tapered HD
#209 027 .035 in. (0.9 mm) #207 313 5/8-in. orifice, tapered 15/16 OD
#209 029 3/64 in. (1.2 mm) #209 035 3/8-in. orifice, tapered
#209 030 1/16 in. (1.6 mm) #209 036 1/2-in. orifice, tapered

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 Optional Consumables–Centerfire Series (Order from Miller Service Parts.) ™

Insulator 10012 Large Nozzles Small Nozzles

4323R N-3414C Copper, 3/4-in. I.D., NS-5818B Brass, 5/8-in. I.D.,
1/4-in. tip recess 1/8-in. tip recess
Diffuser D-1AP (large)
N-3418B Brass, 3/4-in. I.D., NS-1218B Brass, 1/2-in. I.D.,
DS-1AP (small)
1/8-in. tip recess 1/8-in. tip recess
XR™-Pistol-Pro Diffuser Conversion Kits N-3414B Brass, 3/4-in. I.D., NS-1200B Brass, 1/2-in. I.D.,
for .035–1/16 in aluminum 1/4-in. tip recess flush tip
#230 669 For D-1AP diffuser N-5814C Copper, 5/8-in. I.D., NST-3818B Brass, 3/8-in. I.D.,
#230 670 For DS-1AP diffuser 1/4-in. tip recess 1/8-in. tip recess
Diffuser kits must be used to convert N-5818B Brass, 5/8-in. I.D.,
to Centerfire™ Series consumables. Kit 1/8-in. tip recess
includes diffuser and head tube liners. N-5814B Brass, 5/8-in. I.D.,
1/4-in. tip recess
Aluminum-Specific T Series Contact Tips
T-035AL .035 in. (0.9 mm)
T-047AL .047 in. (1.2 mm)
T-062AL 1/16 in. (1.6 mm)

3/4-in.
I.D. 5/8-in.
I.D.

Insulator Diffuser “T” Series Tip 5/8-in. 1/2-in.

#10012 #D-1AP (large) (see chart) I.D. Insulator Diffuser “T” Series Tip I.D.
#4323R #DS-1AP (small) (see chart)
Large Nozzle (see chart) Small Nozzle (see chart)

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 Optional Head Tube Assemblies (Order from Miller Service Parts.)

45 Degree/4 Inch 180 Degree/4 Inch 60 Degree/6 Inch

#255 037 Air-Cooled (standard on Spoolmatic® Pro) with Centerfire™
#255 716 Air-Cooled #246 301 Air-Cooled

45 Degree/6 Inch 180 Degree/6 Inch 180 Degree/4 Inch with Centerfire™
#255 040 Air-Cooled #258 476 Air-Cooled #258 474 Air-Cooled

Heavy-Duty Head Tube

Assemblies
For high-duty-cycle applications.
60 Degree/4 Inch 180 Degree/8 Inch
#231 519 Air-Cooled #255 042 Air-Cooled

45 Degree/6 Inch
Heavy-Duty
#262 206 Air-Cooled
60 Degree/6 Inch Heavy-Duty
60 Degree/6 Inch 45 Degree/10 Inch #262 207 Air-Cooled
#231 518 Air-Cooled Tight Access
#258 295 Air-Cooled
For hard-to-reach welds
where a smaller nozzle
and longer reach is needed.
180 Degree/6 Inch Heavy-Duty
#262 208 Air-Cooled

Flex Neck/10 Inch

#267 517 Air-Cooled
Ideal for hard-to-reach welds.

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 Liners for Optional Head Tube Assemblies (Order from Miller Service Parts.)
Fastip™ Liners for Spoolmatic® Pro and Bernard™ Quik Tip™ Tight-Access Liners
XR™-Pistol-Pro for Spoolmatic® Pro and XR™-Pistol-Pro
(4-inch assemblies) (10-inch assemblies)
M1272 .030 –.040 in. (0.8 –1.0 mm) M1427 .030 –.040 in. (0.8 –1.0 mm)
M1273 3/64 and 1/16 in. (1.2 and 1.6 mm) M1421 3/64 and 1/16 in. (1.2 and 1.6 mm)
(6-inch assemblies) Universal Teflon® Liner Kit
M1430 .030 –.040 in. (0.8 –1.0 mm) #262 707 .030 –.040 in. (0.8 –1.0 mm)
M1365 3/64 and 1/16 in. (1.2 and 1.6 mm) black liners
(8-inch assemblies) #262 705 3/64 and 1/16 in. (1.2 and 1.6 mm)
M1337 .030 –.040 in. (0.8 –1.0 mm) yellow liners
M1338 3/64 and 1/16 in. (1.2 and 1.6 mm) Includes five 14-inch liners and cutter.
Liners can be cut to correct length for any
pistol or gooseneck-style gun. Cutter
provides a straight, clean cut to reduce
shaving and feeding problems.

Teflon® Liner Cutter #258 863

Genuine Miller Accessories ®

Hose and Cable Extension Kits 1/16-Inch (1.6 mm) Wire Kit #230 708
#132 228 25 ft. (7.6 m) Specially designed for 1/16-inch wire.
#132 229 50 ft. (15 m) Includes idler roll, head tube liner and inlet
Extends Spoolmatic Pro away from the guide. Required when running 1/16-inch
control box. Convenient plug-in connections. 50-Degree Curved Nozzle Kit-A #264 064 wires. Not included with standard
Includes gas hose, control cord, and weld (Order from Miller Service Parts.) Spoolmatic Pro gun.
power cable with International-style Directly attaches to Spoolmatic Pro,
insulated connector. XR-Aluma-Pro or XR-Pistol-Pro for access
to confined weld joint areas. Used with
Leather Cable Cover
.030 –1/16 inch (0.8 –1.6 mm) wire. Kit
#241 159 15 ft. (4.6 m)
includes two of each size contact tip to
#241 160 30 ft. (9 m)
accommodate all wire sizes, nozzle adapter
Protects gun hose and cable assembly
kit and curved nozzle. Uses standard
from wear and abrasion. Features full-
straight head tube liner.
length hook-and-loop closure for ease
of maintenance or replacement. Replacement Contact Tips for
50-Degree Curved Nozzle
(Order from Miller Service Parts.)
#148 155 .030- and .035-in.
(0.8 and 0.9 mm) wire
#148 154 .047-in. (1.2 mm) wire
#148 156 1/16-in. (1.6 mm) wire

One-Pound (0.5 kg) Spool Canister 50-Degree Curved Nozzle Insulator Kit
#132 230 #264 066
Ideal for use with XR guns if a small job (Order from Miller Service Parts.)
arises requiring a different wire size and/or Sleeve goes over center of curved nozzle to
wire type that does not justify a 12-inch protect operator from heat. For use with
(305 mm) spool of wire. The XR feed cable is 50-Degree Curved Nozzle Kit-A.
removed if the spool canister is being used.
Canister accommodates 4-inch (102 mm)
spools of wire.

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 Spoolmatic Pro Spool Gun Controls®

Spoolmatic Pro Hook-Up Recommendations

CV Power Supply Spoolmatic Pro
Millermatic® Vintage* Need Module #043 084
Millermatic DVI *, DVI2 *, 210*, 212*
® ™ ™ Need Adapter Cable #195 287
(WFS controlled at machine)
Millermatic® 212 Auto-Set™, 250X*, 251*, 252, 300 w/meters*, Shopmate™ 300 DX Direct Hook-Up
®
AlumaPower MPa, CP Series, Deltaweld Series, Dimension Series, Invision MPa, Regency 250*,
™ ™ ™ ® Need WC-24 #137 549
Shopmaster™*, XMT® Series, PipePro® 304*, Trailblazer® 275, 275 DC*, 302*, 302 Air Pak™, 325
Bobcat™ Series, Miller Legend® 302* Need WC-115A #137 546-01-1
*Discontinued product.

WC-115A Weld Control WC-24 Weld Control #137 549

#137 546 Without contactor Packaged in a compact, lightweight,
#137 546-01-1 With contactor non-metallic enclosure, the WC-24 easily
This control operates on 115 VAC, mounts directly on the power source. It’s
and is designed primarily for CC DC designed for use with Miller CV power
power sources. It can also be used sources supplying 24 VAC and 14-pin
with CV power sources or DC receptacles. The control includes a
engine drives supplying 115 VAC. board-mounted potentiometer which can
When used with a CC source, the alter the drive motor acceleration rate to
control circuit functions in a voltage-sensing mode. When used optimize arc starting performance.
with a CV source, it functions as a constant-speed circuit.
Standard features include a wire run-in control and a drive motor
acceleration control which ensure optimum arc starting performance,
regardless of the type of power source being used. The WC-115A
comes with a 10-foot (3 m), wall-type plug power cord.

Typical Installations
Note: Cords and cables are supplied unless noted otherwise on drawings below. Refer to Owner’s Manual for complete installation instructions.

To connect the Spoolmatic Pro gun and WC-24

control to older-style Miller or competitive CV power 10-ft. (3 m)
sources that do not have a 24 VAC supply, the PSA-2 Miller CV, DC
power source WC-24 Control Cord
control #141 604 is required.
with a 14-pin Control Weld
To connect Spoolmatic Pro gun and WC-24 control to receptacle and Control Cord Power
Millermatic® 200 power source that has a 24 VAC supply Spoolmatic Pro
Cable
4-pin receptacle, order adapter cord #042 236.
40-ft. (12 m) Gas Hose

To connect the WC-115A control to older-style Miller

power sources having Hubbell or 5-pin contactor Gas Hose
control receptacles, the appropriate connector must WC-115A
be ordered separately: Control Control Cord
To connect to older-style Miller CC power sources having Weld Power Cable
a two-socket Hubbell connector, order plug #039 618. Miller and competitive CC and/or
CV, DC power source/generator —
If power source has a Miller 5-pin receptacle, order if the power source does not have
#039 273 and #039 685. Spoolmatic Pro
a weld output contactor, order
To connect to older-style Miller CV power sources having the optional WC-115 contactor.
Weld Power Cable (not included)
a two-prong Hubbell connector, order plug #039 635. 10-ft. (3 m) Contactor Cord
Note: These connectors are to replace the 14-pin (supplied on non-contactor unit)
connector on the 10-foot interconnect contactor cord. 10-ft. (3 m) 115 VAC Power Cord (supplied)
Internal wiring changes may be necessary.

6
Notes

7
 Ordering Information
Equipment Stock No. Description Qty. Price
Important notes:
Spoolmatic Pro Spool Gun
® #301 147 15-ft. (4.6 m) cable
Spoolmatic Pro guns require a
#301 148 30-ft. (9 m) cable
WC-24 or WC-115 weld control,
unless used on a machine that WC-24 Weld Control #137 549
allows direct hookup. Refer to
WC-115A Weld Control #137 546 Without contactor
chart on page 6.
#137 546-01-1 With contactor

Recommended Power Consumables and Accessories

Consumables See pages 2–3
Sources
Optional Head Tube Assemblies See page 4
AlumaPower™ MPa
See literature no. DC/34 Liners for Opt. Head Tube Assemblies See page 5
(For synergic use with AlumaFeed™) Hose and Cable Extension Kits #132 228 25 ft. (7.6 m)
Millermatic® 212 Auto-Set™ #132 229 50 ft. (15 m)
See literature no. DC/12.46 Leather Cable Cover #241 159 15 ft. (4.6 m)
Millermatic® 252 #241 160 30 ft. (9 m)
See literature no. DC/12.49
One-Pound Spool Canister #132 230
(Not compatible with Millermatic 350P)
®
Deltaweld Series 50-Degree Curved Nozzle Kit-A #264 064
See literature no. DC/16.2 Replacement Contact Tips for See page 5
XMT® 350/450 50-Degree Curved Nozzle
See literature no. DC/18.83 50-Degree Curved Nozzle Insulator Kit #264 066 For use with 50-Degree Curved Nozzle Kit-A
Invision™ MPa 1/16-Inch (1.6 mm) Wire Kit #230 708 Required when running 1/16-inch wire
See literature no. DC/23.5
Trailblazer® 275/325 Date: Total Quoted Price:
See literature no. ED/4.75
Big Blue® 800 Duo Air Pak™
See literature no. ED/13.0
Note: Other power sources may be used.

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© 2013 Miller Electric Mfg. Co.