Related Manuals for Miller Electric R-115
Summary of Contents for Miller Electric R-115
- Page 1 Visit our website at www.MillerWelds.com OM-193 471P 2006−05 Processes Description Wire Feeder R-115 MIG (GMAW) Welding Flux Cored (FCAW) Welding File: MIG (GMAW)
- Page 2 ISO 9001:2000 Quality System Standard. 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 specification sheets.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2. -
Page 5: Section 1 − Safety Precautions - Read Before Using
DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. - 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.
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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: Principal Safety Standards
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. - Page 10 LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique −... -
Page 12: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). -
Page 13: Section 3 − Installation
SECTION 3 − INSTALLATION 3-1. Specifications Type of Input Welding Power Power Source Type 115 Volts AC Constant Voltage Single Phase (CV) DC And 2 Amperes 50/60 Contactor Control 3-2. Site Selection Wire Wire Feed Diameter Speed Range Circuit Rating Range .030 To 3/32 in 500 Amperes,... -
Page 14: Gun Recommendation Table
3-3. Gun Recommendation Table Process GMAW − Hard or Corded Wires FCAW − Self-Shielding Wires 3-4. Equipment Connection Diagrams 3-5. Rear Panel Connections And Power Switch Location Tools Needed: 5/8, 11/16 in OM-193 471 Page 10 M25 Or M40 GA-40GL CV Welding Power Source With 115 VAC Power Interconnecting Control Cord... -
Page 15: Connecting Welding Gun And Weld Cable
3-6. Connecting Welding Gun And Weld Cable Tools Needed: 9/16 in Gun Securing Knob Gun Block Gun Outlet Wire Guide Loosen knob, insert gun into block. Position outlet wire guide as close as possible to drive rolls without touching. Tighten knob. Gun Trigger Receptacle Gun Trigger Plug Weld Cable Terminal... -
Page 16: Installing Wire Guide And Drive Roll
3-7. Installing Wire Guide And Drive Roll Tools Needed: 3/8 in OM-193 471 Page 12 Inlet Wire Guide Intermediate Wire Guide Install and secure inlet wire guide, and intermediate wire guide. Drive Roll (4) Install drive rolls and turn drive roll nut one click. -
Page 17: Installing And Threading Welding Wire
3-8. Installing And Threading Welding Wire Tighten WOOD Retaining Ring Hub Tension Adjustment Nut If necessary, move hub on support for use of different size wire spool. Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining ring. Adjust tension nut so wire is taut when wire feed stops. -
Page 18: Interconnecting Power Cord Ground Lead Connection (All Models)
3-9. Interconnecting Power Cord Ground Lead Connection (All Models) Tools Needed: 3/8 in 1/4 in 3-10. Connection For L-TEC Welding Power Sources With 7-Flat Socket Receptacle Tools Needed: 1/4 in OM-193 471 Page 14 Make ground lead connections according to Section 3-9 before following this procedure. -
Page 19: Connection For Hobart Welding Power Sources With 19-Socket Receptacle
3-11. Connection For Hobart Welding Power Sources With 19-Socket Receptacle Tools Needed: 1/4 in 3-12. Connection For L-TEC Welding Power Sources With 19-Socket Receptacle Tools Needed: 1/4 in Make ground lead connections according to Section 3-9 before following this procedure. G F E Make ground lead connections according to Section 3-9 before... -
Page 20: Connection For Hobart Welding Power Sources With 5-Socket And 115 Volt Ac Receptacles
3-13. Connection For Hobart Welding Power Sources With 5-Socket And 115 Volt AC Receptacles Tools Needed: 1/4 in 3-14. Connection For Lincoln Welding Power Sources With 14-Socket Receptacle Tools Needed: 1/4 in OM-193 471 Page 16 Make ground lead connections according to Section 3-9 before following this procedure. -
Page 21: Connection For Lincoln Welding Power Sources With Terminal Strip Connections
3-15. Connection For Lincoln Welding Power Sources With Terminal Strip Connections Tools Needed: 1/4 in 3-16. Connection For AIRCO Welding Power Sources With Two-Prong Twistlock And 115 Volts AC Receptacles Tools Needed: 1/4 in Make ground lead connections according to Section 3-9 before following this procedure. -
Page 22: Connection For Welding Power Sources With Hubbell Receptacles
3-17. Connection For Welding Power Sources With Hubbell Receptacles Tools Needed: 1/4 in 3-18. Connection For Miller Welding Power Sources With 14-Socket Receptacle Tools Needed: 1/4 in OM-193 471 Page 18 Make ground lead connections according to Section 3-9 before following this procedure. -
Page 23: Motor Start/Burnback Control
3-19. Motor Start/Burnback Control Tools Needed: Non-Conductive 1/4 in To change wire feed starting speed proceed as follows: Turn Off unit and welding power source. Remove wrapper. Motor Board PC1 Motor Start Control Potentiometer R73 Remove protective white rubber cap before making adjustment. Adjust potentiometer R73 using a small nonconductive screwdriver. -
Page 24: Section 4 − Operation
SECTION 4 − OPERATION 4-1. Front Panel Controls 4-2. Optional Side Panel Controls OM-193 471 Page 20 Wire Speed Control Jog/Purge Switch Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit shielding gas valve. -
Page 25: Section 5 − Maintenance & Troubleshooting
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Replace Unreadable Labels Gun Cable 5-2. Overload Protection Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Weld Cable Gas Hose 6 Months Clean Drive Rolls Clean And Tighten Weld Terminals Replace... -
Page 26: Troubleshooting
5-3. Troubleshooting Trouble Wire does not feed, unit completely inop- Turn Power switch On. erative. Check circuit breaker CB1 (see Section 5-2). Check Interconnecting control cord connections (see Section 3-9). Check input power. Wire does not feed. Check circuit breaker CB1 (see Section 5-2). Check gun trigger connection at wire feeder. -
Page 27: Section 6 − Electrical Diagram
SECTION 6 − ELECTRICAL DIAGRAM 193 378-C Figure 6-1. Circuit Diagram For Wire Feeder With Optional Equipment OM-193 471 Page 23... -
Page 28: Section 7 − Parts List
SECTION 7 − PARTS LIST Hardware is common and not available unless listed. Item Dia. Part Mkgs....089 899 .. - Page 29 Item Dia. Part Mkgs....044 426 ....228 036 ..
- Page 30 Item Dia. Part Mkgs....602 009 ....172 075 .
- Page 31 NOTE Base selection of drive rolls upon the following recommended usages: 1. V-Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4. V-Knurled rolls for hard shelled cored wires. 5.
- Page 32 Notes OM-193 471 Page 28...
- Page 33 Notes OM-193 471 Page 29...
- Page 34 Notes OM-193 471 Page 30...
- Page 35 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
- Page 36 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2006 Miller Electric Mfg. Co. 2006−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...