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Summary of Contents for Miller R-115
- Page 1 OM-193 471E August 1999 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder R-115 Visit our website at www.MillerWelds.com...
- Page 2 This Owner’s Manual is designed to help you get the most out of your every power source from Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the help you protect yourself against potential hazards on the worksite. We’ve business.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. -
Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message. - Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.
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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. MOVING PARTS can cause injury. 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: Emf Information
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. -
Page 9: Section 1 − Consignes De Securite − Lire Avant Utilisation
SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION som _nd_fre 5/97 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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité... - Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité... -
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- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. -
Page 13: Section 2 − Installation
SECTION 2 − INSTALLATION 2-1. Specifications Wire Type of Input Welding Power Wire Feed Welding Overall Diameter Weight Power Source Type Speed Range Circuit Rating Dimensions Range Length: 23-1/2 in 100 Volts, .030 To 3/32 in (597 mm) 115 Volts AC 500 Amperes, Constant Voltage (0.8 To 2.4 mm) -
Page 14: Gun Recommendation Table
2-3. Gun Recommendation Table Process GMAW − Hard or Corded Wires M25 Or M40 FCAW − Self-Shielding Wires GA-40GL 2-4. Equipment Connection Diagrams CV Welding Power Source With 115 VAC Power Interconnecting Control Cord (Required) Weld Cable (Required) Work 2-5. Rear Panel Connections And Power Switch Location Gas Hose With 5/8-18 Right- hand Thread Fittings (Customer Supplied) -
Page 15: Connecting Welding Gun And Weld Cable
2-6. 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 16: Installing Wire Guide And Drive Roll
2-7. 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 17: Installing And Threading Welding Wire
2-8. 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 18: Interconnecting Power Cord Ground Lead Connection (All Models)
2-9. 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 19: Connection For Hobart Power Sources With 19-Socket Receptacle
2-11. Connection For Hobart Power Sources With 19-Socket Receptacle Terminal Block 1T Make ground lead connections Interconnecting Power Cord according to Section 2-9 before Green Lead (Ground following this procedure. Previously Connected) Connect remaining leads terminal block as follows: A: 115 VAC/Neutral Lead B: 115 VAC/Hot Lead C: No Connection D: Dry Contact Closure w/Respect... -
Page 20: Connection For Hobart Power Sources With 5-Socket And 115 Volts Ac Receptacles
2-13. Connection For Hobart Power Sources With 5-Socket And 115 Volts AC Recepta- cles Terminal Block 1T Make ground lead connections 3-Conductor Cord according to Section 2-9 before 2-Conductor Cord following this procedure. Green Lead (Ground Previously Connected) Connect remaining leads terminal block as follows: A: 115 VAC/Neutral Lead... -
Page 21: Connection For Lincoln Power Sources With Terminal Strip Connections
2-15. Connection For Lincoln Power Sources With Terminal Strip Connections Terminal Block 1T Make ground lead connections Interconnecting Power Cord according to Section 2-9 before Green Lead (Ground following this procedure. Previously Connected) Connect remaining leads terminal block as follows: A: 115 VAC/Neutral Lead B: 115 VAC/Hot Lead C: No Connection... -
Page 22: Connection For Welding Power Sources With Hubbell Receptacles
2-17. Connection For Welding Power Sources With Hubbell Receptacles Terminal Block 1T Make ground lead connections Interconnecting Power Cord according to Section 2-9 before Green Lead (Ground following this procedure. Previously Connected) Connect remaining leads terminal block as follows: A: 115 VAC/Neutral Lead B: 115 VAC/Hot Lead C: No Connection D: No Connection... -
Page 23: Motor Start/Burnback Control
2-18. 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 24: Section 3 − Operation
SECTION 3 − OPERATION 3-1. 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 25: Section 4 − Maintenance & Troubleshooting
SECTION 4 − MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Y 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 26: Troubleshooting
4-3. Troubleshooting Trouble Remedy Wire does not feed, unit completely inop- Turn Power switch On. erative. Check circuit breaker CB1 (see Section 4-2). Check Interconnecting control cord connections (see Section 2-9). Check input power. Wire does not feed. Check circuit breaker CB1 (see Section 4-2). Check gun trigger connection at wire feeder. -
Page 27: Section 5 − Electrical Diagram
SECTION 5 − ELECTRICAL DIAGRAM 193 378-C Figure 5-1. Circuit Diagram For Wire Feeder With Optional Equipment OM-193 471 Page 23... -
Page 28: Section 6 − Parts List
SECTION 6 − PARTS LIST Hardware is common and not available unless listed. 802 305-B Figure 6-1. Main Assembly Item Dia. Part Mkgs. Description Quantity Figure 6-1. Main Assembly ....089 899 . - Page 29 ... 011 244 . . . CIRCUIT BREAKER, man reset 1P 2A 250VAC ..... . Item Dia.
- Page 30 Item Dia. Part Mkgs. Description Quantity Figure 6-2. Drive Assembly, Wire (Fig 7-2 Item 1) ....602 009 . . . SCREW, .250-20 x 1.250 soc hd hex gr 8 .
- Page 31 Table 6-1. Drive Roll & Wire Guide Kits 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.
- 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 Effective January 1, 1999 (Equipment with a serial number preface of KK" or newer) Warranty Questions? This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Call LIMITED WARRANTY − Subject to the terms and conditions APT, ZIPCUT &...
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Page 36: Options And Accessories
File a claim for loss or damage during Contact the Delivering Carrier for: shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 1999 Miller Electric Mfg. Co. 7/99...
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