Miller Electric M-15 Owner's Manual
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Miller Electric M-15 Owner's Manual

Arc welding power source and wire feeder
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www.MillerWelds.com
Millermatic Challenger
And M-15 Gun
OM-1314
February 1997
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And Wire
Feeder
R
180 846A

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Summary of Contents for Miller Electric M-15

  • Page 1 Millermatic Challenger Visit our website at www.MillerWelds.com And M-15 Gun OM-1314 180 846A February 1997 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder...
  • Page 2 ISO 9001 Quality System Standard. service information for your particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Additional Symbols For Installation, Operation, And Maintenance 1-4. Principal Safety Standards WARNING 1-5. EMF Information SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION This product, when used 1-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’...

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique –...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

  • Page 13: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Rated Welding Amperage Output Range 130 A @ 20.5 Volts 40 – 170 DC, 30% Duty Cycle Solid/ Stainless Wire Type And Dia .023 – .035 in (0.6 – 0.9 mm) * While idling 2-2.

  • Page 14: Duty Cycle And Overheating

    2-3. Duty Cycle And Overheating Overheating OM-1314 Page 10 25 30 50 60 70 80 100 % DUTY CYCLE 30% Duty Cycle At 130 Amperes 3 Minutes Welding 7 Minutes Resting Minutes Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.

  • Page 15: Installing Work Clamp

    2-4. Installing Work Clamp Tools Needed: 3/8, 7/16 in 2-5. Installing Gas Supply Tools Needed: 5/8, 1-1/8 in Argon Gas Insulator Bolt Smaller Hole Work Clamp Tabs Bend tabs around work cable. Work Cable From Unit Ref. ST-025 190-D Obtain gas cylinder and chain to running gear, wall, or other station- ary support so cylinder cannot fall and break off valve.

  • Page 16: Installing Welding Gun And Setting Gun Polarity For Wire Type

    2-6. Installing Welding Gun And Setting Gun Polarity For Wire Type Follow wire manufacturer’s recommendation. Flux Cored Wires (FCAW–Without Gas) Straight Polarity DCEN OM-1314 Page 12 Solid Steel Or Aluminum Wires (GMAW–With Gas) Reverse Polarity DCEP Front Panel Openings Gun Opening Gun Trigger Receptacle Gun Securing Nut Drive Assembly...

  • Page 17: Electrical Service Guide

    2-7. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) 2-8.

  • Page 18: Installing Wire Spool And Adjusting Hub Tension

    2-9. Installing Wire Spool And Adjusting Hub Tension 1 Lb Wire Spool Standard Wire Spool Standard Wire Reel Part No. 183 312 Part No. 135 615 When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in S-0499 OM-1314 Page 14...

  • Page 19: Installing Drive Roll And Threading Welding Wire

    2-10. Installing Drive Roll And Threading Welding Wire Install drive roll. Open pressure assembly. Push wire thru guides into gun; continue to hold wire. Close and tighten pressure assembly, and let go of wire. Turn power On. Reinstall contact tip and nozzle. Tools Needed: For Flux Cored Wire For Solid Wire...

  • Page 20: Weld Parameters

    2-11. Weld Parameters Wire Type, Wire Type, Wire Wire Operator Shielding Gas, Diameter Controls And Flow Rate (inch) Voltage Tap .023 Wire Speed E70S-6 Voltage Tap .030 Wire Speed 20 cfh+ 20 cfh+ Voltage Tap .035 Wire Speed Voltage Tap .023 Wire Speed E70S-6...

  • Page 21: Section 4 - Maintenance & Troubleshooting

    SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Maintenance Replace Damaged Or Unreadable Labels 4-2. Fuse F1 Tools Needed: 3/8 in 4-3. Short Circuit Shutdown If contact tip is shorted and sticks to workpiece, the unit shuts down, but fan runs. To resume operation, release gun trigger, turn Off unit, and remove contact tip from workpiece.

  • Page 22: Replacing Gun Contact Tip

    4-4. Replacing Gun Contact Tip Tools Needed: 4-5. Unicable Repair To repair or replace unicable, order Unicable Clamp Kit, part number 172 017. Kit includes all required instructions, clamps, inner support tube, compression clip, switch leads, and connectors. OM-1314 Page 18 Y Turn replacing contact tip.

  • Page 23: Cleaning Or Replacing Gun Liner

    4-6. Cleaning Or Replacing Gun Liner 3/8 in Lay gun cable out straight before installing new liner. Y Disconnect gun from unit. Head Tube Remove nozzle, contact tip, adapter, and wire outlet guide. Blow out gun casing. Tools Needed: 3/8 in Wire Outlet Guide Remove liner.

  • Page 24: Replacing Switch And/Or Head Tube

    4-7. Replacing Switch And/Or Head Tube Remove handle locking nut. Secure head Remove shock washers tube in vice. from front and rear of head tube. Install both existing shock washers to new head tube and hand-tighten head tube into connector cable. Tools Needed: 3/4 in OM-1314 Page 20...

  • Page 25: Cleaning Or Repairing Drive Assembly

    4-8. Cleaning Or Repairing Drive Assembly Tools Needed: 5/64 in Y Turn power before cleaning or repairing drive assembly. Wire Spool Nozzle Cut welding wire off at nozzle. Retract wire onto spool and secure. Pressure Roll Arm Cotter Pin Screw Bearing Remove bearing.

  • Page 26: Troubleshooting

    4-9. Troubleshooting Welding Trouble No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-8). Check and replace power switch if necessary. Check fuse F1, and replace if necessary (see Section 4-2). Replace building line fuse or reset circuit breaker if open (see Section 2-8). Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section 2-6 and/or 4-7).

  • Page 27: Section 5 - Electrical Diagram

    SECTION 5 – ELECTRICAL DIAGRAM SB-180 784-B Figure 5-1. Circuit Diagram OM-1314 Page 23...

  • Page 28: Section 6 - Mig Welding (Gmaw) Guidelines

    SECTION 6 – MIG WELDING (GMAW) GUIDELINES 6-1. Typical MIG Process Connections Regulator/ Flowmeter Shielding Gas OM-1314 Page 24 Wire Feeder/ Power Source Work Clamp Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle.

  • Page 29: Typical Mig Process Control Settings

    6-2. Typical MIG Process Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. .035 in Wire Recommendation Size...

  • Page 30: Holding And Positioning Welding Gun

    6-3. Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. End View Of Work Angle End View Of Work Angle OM-1314 Page 26...

  • Page 31: Conditions That Affect Weld Bead Shape

    6-4. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Short Short FILLET WELD ELECTRODE EXTENSIONS (STICKOUT) Slow Push Perpendicular...

  • Page 32: Gun Movement During Welding

    6-5. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 6-6. Poor Weld Bead Characteristics 6-7.

  • Page 33: Troubleshooting - Excessive Spatter

    6-8. Troubleshooting – Excessive Spatter Possible Causes Wire feed speed too high. Voltage too high. Electrode extension (stickout) too long. Workpiece dirty. Insufficient shielding gas at welding arc. Dirty welding wire. 6-9. Troubleshooting – Porosity Possible Causes Insufficient shielding gas at welding arc. Wrong gas.

  • Page 34: Troubleshooting - Lack Of Penetration

    6-11. Troubleshooting – Lack Of Penetration Lack of Penetration Good Penetration Possible Causes Improper joint preparation. Improper weld technique. Insufficient heat input. 6-12. Troubleshooting – Incomplete Fusion Possible Causes Workpiece dirty. Insufficient heat input. Improper welding technique. 6-13. Troubleshooting – Burn-Through Possible Causes Excessive heat input.

  • Page 35: Troubleshooting - Waviness Of Bead

    6-14. Troubleshooting – Waviness Of Bead Possible Causes Welding wire extends too far out of nozzle. Unsteady hand. 6-15. Troubleshooting – Distortion Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input. Waviness Of Bead – weld metal that is not parallel and does not cover joint formed by base metal.

  • Page 36: Common Mig Shielding Gases

    6-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
  • Page 37 Notes OM-1314 Page 33...

  • Page 38: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. ST-801 633 Figure 7-1. Main Assembly OM-1314 Page 34...
  • Page 39 ........M-15 GUN, (Fig 7-2) .
  • Page 40 Hardware is common and not available unless listed. *Includes Item 17 OM-1314 Page 36 Figure 7-2. M-15 Gun ST-801 140...
  • Page 41 Item Part 169 589 Figure 7-2. M-15 Gun (Fig 7-1 Item 43) ..169 715 NOZZLE, slip type .500 orf flush ..176 237 NOZZLE, spot flat . . .
  • Page 42 Item Dia. Part Mkgs. Figure 7-3. Drive Assembly, Wire (Fig 7-1 Item 1) . . . 173 446 . . . MOTOR ... 129 893 . . . INSULATOR, housing drive .
  • Page 43 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 44: Owner's Record

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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