Instruction/ maintenance manual of the product R-115 Miller Electric
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Processes Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding Wire Feeder OM-193 471P 2006 − 05 R-1 15 V isit our website at www.MillerWelds.
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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-193 471 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown i n the adjoining symbols.
OM-193 471 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
OM-193 471 Page 3 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.
OM-193 471 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .
OM-193 471 Pa ge 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
OM-193 471 Page 6 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.
OM-193 471 Pa ge 7 2-3 . Dange rs suppléme ntaire s en r e lation avec l’installa tion, le f onc tionneme nt e t l a maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables.
OM-193 471 Page 8 2-5. Princi pales nor mes de sécur ité Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .
OM-193 471 Page 9 SECTION 3 − INST ALLA TION 3-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating Overall Dimensions W eight 1 1 5 V olts AC Single Phase 2 Amperes 50/60 Hz Constant V oltage (CV) DC And Contactor Control 75 to 750 ipm (1.
OM-193 471 Page 10 3-3. Gun Recommendation T able Process Gun GMA W − Hard or Corded Wires M25 Or M40 FCA W − Self-Shielding Wires GA-40GL 1 CV Welding Power Source With 1 15 V AC Power 2 Interconnecting Control Cord (Required) 3 Weld Cable (Required) 4 W ork 3-4.
OM-193 471 Page 1 1 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob, insert gun into block. Position outlet wire guide as close as possible to drive rolls without touching. T ighten knob. 4 Gun Trigger Receptacle 5 Gun Trigger Plug 6 Weld Cable T erminal 7 Weld Cable From W elding Power Source 3-6.
OM-193 471 Page 12 3-7. Installing Wire Guide And Drive Roll 802 310-A 1 Inlet Wire Guide 2 Intermediate Wire Guide Install and secure inlet wire guide, and intermediate wire guide. 3 Drive Roll (4) Install drive rolls and turn drive roll nut one click.
OM-193 471 Page 13 3-8. Installing And Threading W elding Wire T ools Needed: 1 Retaining Ring 2 Hub T ension 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.
OM-193 471 Page 14 3-9. Interconnecting Power Cord Ground Lead Connection (All Models) Ref. 802 310 . 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.
OM-193 471 Page 15 3-1 1. Connection For Hobart Welding Power Sources With 19-Socket Receptacle Ref. 802 310 / Ref. 193 749 1 T erminal Block 1T 2 Interconnecting Power Cord 3 Green Lead (Connected T .
OM-193 471 Page 16 3-13. Connection For Hobart Welding Power Sources With 5-Socket And 1 15 V olt AC Receptacles Ref. 802 310 / Ref. 193 749 1 T erminal Block 1T 2 3-Conductor Cord 3 2-Conductor Cord .
OM-193 471 Page 17 3-15. Connection For Lincoln W elding Power Sources With T erminal Strip Connections Ref. 802 310 / Ref. 193 749 1 T erminal Block 1T 2 Interconnecting Power Cord 3 Green Lead (Conn.
OM-193 471 Page 18 3-17. Connection For W elding Power Sources With Hubbell Receptacles Ref. 802 310 / Ref. 193 749 1 T erminal Block 1T 2 Interconnecting Power Cord 3 Green Lead (Connected T o Ground.
OM-193 471 Page 19 3-19. Motor Start/Burnback Control Ref. 802 310 / 192 653 T o change wire feed starting speed proceed as follows: T urn Off unit and welding power source. Remove wrapper . 1 Motor Board PC1 2 Motor Start Control Potentiometer R73 Remove protective white rubber cap before making adjustment.
OM-193 471 Page 20 SECTION 4 − OPERA TION 4-1. Front Panel Controls 1 Wire Speed Control 2 Jog/Purge Switch Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas valve.
OM-193 471 Page 21 SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Clean And T ighten W eld T erminal.
OM-193 471 Page 22 5-3. T roubleshooting T rouble Remedy Wire does not feed, unit completely inop- erative. T urn Power switch On. Check circuit breaker CB1 (see Section 5-2). Check Interconnecting control cord connections (see Section 3-9). Check input power .
OM-193 471 Page 23 SECTION 6 − ELECTRICAL DIAGRAM 193 378-C ROUTE WELD CABLE THROUGH REED SWITCH ASSEMBL Y NOTE: Figure 6-1. Circuit Diagram For Wire Feeder With Optional Equipment.
OM-193 471 Page 24 SECTION 7 − P ARTS LIST . Hardware is common and not available unless listed. 802 305-D 19 29 28 30 32 31 27 26 25 23 24 22 36 17 18 16 15 2 33 34 35 1 38 37 3 5 21 20 14 13 12 11 10 9 10 6 8 7 9 4 39 Figure 7-1. Main Assembly Description Part No.
OM-193 471 Page 25 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly (Continued) Quantity 18 044 426 CONNECTOR, clamp cable 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-193 471 Page 26 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Drive Assembly , Wire (Fig 7-2 Item 1) Quantity 1 602 009 SCREW , .250-20 x 1.250 soc hd hex gr 8 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-193 471 Page 27 T able 7-1. 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).
OM-193 471 Page 28 Notes.
OM-193 471 Page 29 Notes.
OM-193 471 Page 30 Notes.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters.
An important point after buying a device Miller Electric R-115 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric R-115 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric R-115 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric R-115 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric R-115 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric R-115, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric R-115.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric R-115. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric R-115 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
