Miller Millermatic Pulser M-15 Gun Owner's Manual
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Miller Millermatic Pulser M-15 Gun Owner's Manual

Miller Millermatic Pulser M-15 Gun Owner's Manual

Arc welding power source and wire feeder
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Millermatic Pulser
M-15 Gun And Spoolmate
3035 Spool Gun
OM-1322
March 2004
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R
200 070N

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Summary of Contents for Miller Millermatic Pulser M-15 Gun

  • Page 1 OM-1322 200 070N March 2004 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic Pulser M-15 Gun And Spoolmate 3035 Spool Gun Visit our website at www.MillerWelds.com...
  • 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 catalog sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 6 − ELECTRICAL DIAGRAM ............SECTION 7 −...

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 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.

  • 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: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org).

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance.
  • Page 10 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.

  • Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à...

  • Page 12: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.org).

  • Page 13: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Welding Power Source And MIG Gun Specifications Max. Open Amps Input at Rated Output, 50 or 60 Hz, Single-Phase Rated Output Rated Output Amperage Amperage Circuit Circuit 200 (208) V 230 V 240 V Voltage DC Range DC 160 A at 26 VDC, 30-200...

  • Page 14: Welding Power Source Duty Cycle And Overheating

    3-3. Welding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.

  • Page 15: Spool Gun Duty Cycle And Overheating

    3-5. Spool Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. Do not weld at rated load longer than shown below. Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Definition .023 To .035 in (0.6 To 0.9 mm) Aluminum Wire .023 To .035 in (0.6 To 0.9 mm) Hard Or Flux Cored Wires...

  • Page 16: Installing Cylinder Rack Wheels

    3-7. Installing Cylinder Rack Wheels Slide Chain Into Slot Remove paint from axle grooves before ins talling retaining rings. 803 261-A Welding Power Source Install supplied chains onto dual bracket. Washer Block front casters to prevent movement. Dual Cylinder Rack Retaining Ring Block up rear of unit.

  • Page 17: Installing Work Clamp

    3-8. Installing Work Clamp Work Cable Boot Route cable through front panel opening. Slide boot onto work cable. Negative (−) Output Terminal Connect cable to terminal and cover connection with boot. Close door. PULSE − Tools Needed: 203006 1/2, 3/4 in 802 713-B 3-9.

  • Page 18: Connecting A Spool Gun

    3-10. Connecting A Spool Gun Barbed Fitting If spool gun gas hose is equipped with a pre-installed barbed fitting, cut off fitting from end of hose. Connect spool gun gas hose to barbed fitting. Pulse Weld Terminal Connect spool gun cable to pulse weld terminal.

  • Page 19: Installing Gas Supply

    3-12. Installing Gas Supply Obtain gas cylinders and chain to running gear, wall, or other stationary support so cylinders cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter Cylinder Valve with CO shielding gas. See Parts List for optional gas regulator/flowmeter.

  • Page 20: Installing Mig Wire Spool And Adjusting Hub Tension

    3-13. Installing MIG Wire Spool and Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in ST-072573-B OM-1322 Page 16 Return To Table Of Contents...

  • Page 21: Installing Spool Gun Wire Spool And Threading Welding Wire

    3-14. Installing Spool Gun Wire Spool And Threading Welding Wire Thumb Screw Spool Cover Remove thumb screw and spool Tools Needed: cover. Hub Tension Nut Wire Spool Install spool so wire feeds from top. Turn hub tension nut just so a slight drag is felt on the wire spool.

  • Page 22: Positioning Jumper Links

    3-15. Positioning Jumper Links Check input voltage available at Before setting jumper link, check input voltage and link site and listed on the machine rating unit for voltage closest to the input voltage at the site. label. Jumper Links Access Door Open door.

  • Page 23: Selecting A Location And Connecting Input Power

    3-17. Selecting A Location And Connecting Input Power Rating Label Supply correct input power. Plug (NEMA Type 6-50P) Receptacle (NEMA Type 6-50R) Connect plug to receptacle. Input And Grounding 18 in (457 mm) of Y Do not move or operate unit Conductors space for airflow where it could tip.

  • Page 24: Threading Welding Wire

    3-18. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open pressure assembly.

  • Page 25: Installing Optional Curved Or 9 In Straight Barrel On Spoolmate 3035 Spool Gun

    3-19. Installing Optional Curved Or 9 in Straight Barrel On Spoolmate 3035 Spool Gun Y Turn Off and disconnect input power. Contact Adapter Remove existing barrel from contact adapter. Gas Hose Disconnect gas hose from gas nipple. Straight Barrel Curved Barrel Locking Nut Before tightening locking nut on the curved barrel, the barrel...

  • Page 26: Using Gun/Cable Holder

    3-20. Using Gun/Cable Holder Side Panel Latch Cable Holder Press latch down to release and open door. Holster (2) Wrap cable around cable holder, and place gun nozzle into holster. 802 726 OM-1322 Page 22 Return To Table Of Contents...

  • Page 27: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls WIRE SPEED VOLTAGE RATED OUTPUT AMPERA GE VOL TAGE DUTY CYCLE MAX OCV NEMA CLASS I (60) DO NO T SWITCH WHILE WELDING −1 −2 −3 −4 −5 ARC LENGTH ( PULSE ONL PULSE ONLY ) MIG GUN SPOOL GUN 200 034-B...

  • Page 28: Weld Parameter Chart

    4-2. Weld Parameter Chart 3035 *Line voltage can affect weld output, settings on this chart are starting values only. You may need to adjust voltage and wire feed speed to optimize your settings. Input Line Parameter Voltage* Chart Settings Higher Weld Will Be e.g.
  • Page 29 3035 200 796-A Return To Table Of Contents OM-1322 Page 25...

  • Page 30: Parameter Adjustment Guide

    4-3. Parameter Adjustment Guide Problem Probable Cause Remedy Erratic arc, ball at end of wire Arc Length control set too low. Increase arc length setting slightly (see Section 4-1). too large at time of transfer to weld puddle. Wire shorting (stubbing) into Wire speed set too high.

  • Page 31: Section 5 − Maintenance &Troubleshooting

    SECTION 5 − MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Remove drive roll and Blow out or vacuum inside.

  • Page 32: Replacing Gun Contact Tip

    5-4. Replacing Gun Contact Tip Y Turn Off power. Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: Ref. 800 797-C 5-5. Changing Drive Roll and Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw.

  • Page 33: Aligning Drive Rolls And Wire Guide

    5-6. Aligning Drive Rolls and Wire Guide Y Turn Off power. View is from top of drive rolls look- ing down with pressure assembly open. Drive Roll Securing Nut Correct Incorrect Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide.

  • Page 34: Cleaning Or Replacing Gun Liner

    5-8. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit first. 5/16 in, 10 mm Head Tube Remove nozzle, contact tip, and adapter. 5/16 in 10 mm Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Blow out gun casing.

  • Page 35: Replacing Switch And/Or Head Tube

    5-9. Replacing Switch And/Or Head Tube Y Disconnect gun first. Remove handle locking nut. Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure.

  • Page 36: Changing Drive And Push Rolls On Spoolmate 3035

    5-10. Changing Drive And Push Rolls On Spoolmate 3035 Y Turn Off power at welding power source first. Drive Roll Cover Remove cover. Changing Push Roll: To remove push roll: Push Roll Screw Washer Push Roll Remove screw and washer, and lift out push roll.

  • Page 37: Changing Liner On Spoolmate 3035

    5-11. Changing Liner On Spoolmate 3035 Y Turn Off power at welding power source first. Nozzle Contact Tip Liner Remove and replace liner. Reinstall parts as shown. Tools Needed: Ref. 801 891-A 5-12. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 3-17).

  • Page 38: Spool Gun Troubleshooting

    Trouble Remedy Low, high, or erratic wire speed. Readjust front panel settings (see Section 4-1). Change to correct size drive rolls (see Section 5-5). Readjust drive roll pressure (see Section 3-18). Replace inlet guide, contact tip, and/or liner if necessary (see Sections 5-4 and 5-8). Check position of input jumper links (see Section 3-15).

  • Page 39: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 203 535-B Figure 6-1. Welding Power Source Circuit Diagram OM-1322 Page 35 Return To Table Of Contents...
  • Page 40 186 451 Figure 6-2. Spool Gun Circuit Diagram OM-1322 Page 36 Return To Table Of Contents...

  • Page 41: Section 7 − Mig Welding (Gmaw) Guidelines

    SECTION 7 − MIG WELDING (GMAW) GUIDELINES 7-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery Regulator/ cables before welding on a Flowmeter vehicle. Place work clamp as close to the weld as possible. Shielding Supply Wire Feeder/...

  • Page 42: Typical Mig Process Control Settings

    7-2. 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 1/8 or parameters.

  • Page 43: Holding And Positioning Welding Gun

    7-3. 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. Hold Gun and Control Gun Trigger Workpiece...

  • Page 44: Conditions That Affect Weld Bead Shape

    7-4. 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. Push Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...

  • Page 45: Gun Movement During Welding

    7-5. 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. Stringer Bead − Steady Movement Along Seam Weave Bead −...

  • Page 46: Troubleshooting − Excessive Spatter

    7-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.

  • Page 47: Troubleshooting − Lack Of Penetration

    7-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.

  • Page 48: Troubleshooting − Waviness Of Bead

    7-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand.

  • Page 49: Common Mig Shielding Gases

    7-16. 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 50 Problem Probable Cause Remedy Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn Welding arc not stable. drive rolls if necessary. Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
  • Page 51 Notes Return To Table Of Contents OM-1322 Page 47...

  • Page 52: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 802 718-B Figure 8-1. Main Assembly OM-1322 Page 48 Return To Table Of Contents...
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ....Fig 8-2 BAFFLE,CENTER ...........
  • Page 54 Hardware is common and not available unless listed. 802 719 Figure 8-2. Baffle, Center w/Components OM-1322 Page 50 Return To Table Of Contents...
  • Page 55 Item Dia. Part Mkgs. Description Quantity Figure 8-2. Baffle, Center w/Components (Fig 8-1 Item 1) ......SPOOL HUB ASSEMBLY,(INCLUDING) .
  • Page 56 Hardware is common and not available unless listed. 802 728-B Figure 8-3. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 8-3. Panel, Rear w/Components (Fig 8-1 Item 2) ... . . 049399 NUT, 312−18 PUSH ON .63D .07H STL .
  • Page 57 Hardware is common and not available unless listed. 802 720-A Figure 8-4. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 8-4. Panel, Front w/Components (Fig 8-1 Item 19) ... . . 208475 LABEL,NAMEPLATE MILLERMATIC PULSER .
  • Page 58 Item Part Description Quantity 169591 Figure 8-5. M-15 Gun (Fig 8-1 Item 36) ... . . 169715 NOZZLE,SLIP TYPE .500 ORF FLUSH ....... .
  • Page 59 Item Dia. Part Mkgs. Description Quantity Figure 8-6. Wire Drive And Gears (Fig 8-2 Item 25) 197633 ... . . 602009 SCREW,.250-20 x 1.25 soc hd gr 8 ........
  • Page 60 Hardware is common and not available unless listed. 801 900-C Figure 8-7. Spool Gun Assembly OM-1322 Page 56 Return To Table Of Contents...
  • Page 61 Item Dia. Part Quantity Mkgs. Description 195 016 Figure 8-7. Spool Gun Assembly (Fig 8-1 Item 19) ..186416 TRIGGER SWITCH ..........
  • Page 62 802 532 Figure 8-8. Optional Barrel Assembly Quantity Curved Straight Item Part Description 198 371 198 372 Figure 8-8. Optional Barrel Assembly ... . . 197570 PIN,ANTIROTATION .078 DIA X 3/16 LG .

  • Page 63: Drive Roll And Wire Guide Kits

    8-9. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire. U-Grooved rolls for soft and soft shelled cored wires. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). V-Knurled rolls for hard shelled cored wires.
  • Page 64 Notes...
  • Page 65 Notes...
  • Page 66 Notes...
  • Page 67 Call LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER APT & SAF Model Plasma Cutting Torches to its original retail purchaser that new Miller equipment sold...

  • Page 68: Options And Accessories

    FAX: 44 (0) 1204-598066 www.MillerWelds.com 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. PRINTED IN USA 2004 Miller Electric Mfg. Co. 1/03...

This manual is also suitable for:

Spoolmate 3035 spool gunMillermatic pulserM-15Spoolmate 3035

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