Miller R-115 Owner's Manual
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Miller R-115 Owner's Manual

Miller R-115 Owner's Manual

Universal, constant-speed, semi-automatic wire feeder
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R-115
OM-193471X
2016−10
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
File: MIG (GMAW)

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Summary of Contents for Miller R-115

  • Page 1 OM-193471X 2016−10 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder R-115 File: MIG (GMAW) For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
  • Page 3 ......5-16. Connection For Miller Welding Power Sources With 14-Socket Receptacle .....

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

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

    D Placer les bouteilles debout en les fixant dans un support station- déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par naire ou dans un porte-bouteilles pour les empêcher de tomber ou induction.

  • Page 12: Proposition Californienne 65 Avertissements

    D N’utiliser que les pièces de rechange recommandées par le LE SOUDAGE À L’ARC risque de constructeur. provoquer des interférences. D Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de D L’énergie électromagnétique risque l’industrie, ainsi que les codes municipaux.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 14 Do not weld on drums or any closed containers. Safe64 2012−06 Do not remove or paint over (cover) the label. Safe20 2012−05 Drive rolls can injure fingers. Safe32 2012−05 Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away. Safe33 2012−05 Wear hat and safety glasses.

  • Page 15: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Variable Output Set Up Inductance Duty Cycle Preflow Time Increase Line Connection Process Input Conventional Time Constant Current Load Voltage Trigger Hold Off Postflow Time Wire Feed Cold Jog (Inch) Primary Current Towards...

  • Page 16: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.

  • Page 17: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting A Location Do not put feeder where welding wire hits cylinder. Wire feeder shown is repre- sentative only and may not reflect actual unit. Wire Feeder Rubber Feet Choose slot that allows all rubber feet to sit securely on top of welding power source.

  • Page 18: Equipment Connection Diagrams

    5-2. Equipment Connection Diagrams CV Welding Power Source With 115 VAC Power Interconnecting Control Cord (Required) Weld Cable (Required) Work 5-3. Rear Panel Connections And Power Switch Location Gas Hose With 5/8-18 Right- hand Thread Fittings (Customer Supplied) Shielding gas pressure not to exceed 100 PSI (689 kPa).

  • Page 19: Connecting Welding Gun And Weld Cable

    5-4. Connecting Welding Gun And Weld Cable 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 Weld Cable From Welding...

  • Page 20: Installing Wire Guide And Drive Roll

    5-5. Installing Wire Guide And Drive Roll 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. During maintenance intervals, remove drive rolls, and clean grooves using a wire brush.

  • Page 21: Installing And Threading Welding Wire

    5-6. Installing And Threading Welding Wire 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 22: Interconnecting Power Cord Ground Lead Connection (All Models)

    5-7. Interconnecting Power Cord Ground Lead Connection (All Models) The interconnecting power cord is not supplied with the unit. Be sure to obtain the prop- er interconnecting power cord for the welding power source the wire feeder is being con- nected to.

  • Page 23: Connection For Hobart Welding Power Sources With 19-Socket Receptacle

    5-9. Connection For Hobart Welding Power Sources With 19-Socket Receptacle Terminal Block 1T Make ground lead connections Interconnecting Power Cord according to Section 5-7 before Green Lead (Connected To following this procedure. Ground In Section 5-7) Connect remaining leads terminal block as follows: A: 115 VAC/Neutral Lead B: 115 VAC/Hot Lead C: No Connection...

  • Page 24: Connection For Hobart Welding Power Sources With 5-Socket And 115 Volt Ac Receptacles

    5-11. Connection For Hobart Welding Power Sources With 5-Socket And 115 Volt AC Receptacles Terminal Block 1T Make ground lead connections 3-Conductor Cord according to Section 5-7 before following this procedure. 2-Conductor Cord Green Lead (Connected To Ground In Section 5-7) Connect remaining leads...

  • Page 25: Connection For Lincoln Welding Power Sources With Terminal Strip Connections

    5-13. Connection For Lincoln Welding Power Sources With Terminal Strip Connections Terminal Block 1T Make ground lead connections Interconnecting Power Cord according to Section 5-7 before Green Lead (Connected To following this procedure. Ground In Section 5-7) Connect remaining leads terminal block as follows: A: 115 VAC/Neutral Lead B: 115 VAC/Hot Lead...

  • Page 26: Connection For Welding Power Sources With Hubbell Receptacles

    Connect remaining end of cord to welding power source. Tools Needed: 1/4 in. Ref. 802 310 / Ref. 193 749 5-16. Connection For Miller Welding Power Sources With 14-Socket Receptacle Terminal Block 1T Interconnecting Power Cord Make ground lead connections White Lead...

  • Page 27: Motor Start/Burnback Control

    5-17. Motor Start/Burnback Control 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 28: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Front Panel Controls 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. Use Purge position to momentarily energize gas valve to purge air from gun or adjust gas regulator.

  • Page 29: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. 3 Months Repair Or Clean And Replace Replace Tighten Unreadable Cracked Weld Labels Weld Cable Terminals Replace Cracked Parts Gun Cable Gas Hose 6 Months Blow Out Or Vacuum Clean Inside, Drive...

  • Page 30: Troubleshooting

    7-3. Troubleshooting Trouble Remedy Wire does not feed, unit completely inop- Turn Power switch On. erative. Check supplementary protector CB1 (see Section 7-2). Check Interconnecting control cord connections (see Section 5-7). Check input power. Wire does not feed. Check supplementary protector CB1 (see Section 7-2). Check gun trigger connection at wire feeder.

  • Page 31: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM 193 378-C Figure 8-1. Circuit Diagram For Wire Feeder With Optional Equipment OM-193471 Page 27...

  • Page 32: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 802 305-E Figure 9-1. Main Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ....089899 .
  • Page 33 194308 . . . Label, Miller 8.250 X 3.500 Horizontal (Blk/Wht) ..... . +When ordering a component originally displaying a precautionary label, the label should also be ordered.
  • Page 34 Item Dia. Part Mkgs. Description Quantity Figure 9-2. Drive Assembly, Wire (Fig 9-2 Item 1) ....602009 . . . Screw, .250-20 X 1.250 Soc Hd Hex Gr 8 .
  • Page 35 Table 9-1. Drive Roll & Wire Guide Kits 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.
  • Page 36 Notes OM-193471 Page 32...
  • Page 37 Notes...
  • Page 38 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org...
  • Page 39 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 40 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

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