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OM-1313 179 084P
September 2001
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
And Wire Feeder
Millermatic 185
And M-15 Gun
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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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. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 2 – INSTALLATION 2-1. Specifications Amperes Input at Rated Load Maximum Rated Welding Amperage Overall Output, 60 Hz, Weight Open-Circuit Output Range Dimensions Single-Phase V Voltage DC oltage DC 200 V 230 V KVA KW Length: 36 in (915 mm) 150 A @ 23 Volts 165 lb Width: 18 in 30 – 185 33 30 (1.6)* 26 (1.4)* 6 (0.27)* 5 (0.13)* DC, 60% Duty Cycle (75 kg) (457 mm) Height: 27 in (686 mm) Wire Type And Diameter Calculated Wire Speed Max Wire Feed Speed Solid Steel / Range At No Load While W
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2-3. 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. Reduce amperage or voltage, or duty cycle before welding. Exceeding duty cycle can damage unit and void warranty. 60% Duty Cycle At 150 Amperes 6 Minutes Welding 4 Minutes Resting Overheating A or V 0 15 OR Reduce Duty Cycle Minutes du
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2-5. Installing Work Clamp 1 Work Cable 2 Boot Slide boot onto work cable. Route cable out front panel opening from inside. 4 3 Negative (–) Output Terminal Connect cable to terminal and cover connection with boot. 5 4 Hardware 5 Work Clamp Route cable through clamp handle and secure as shown. 1 2 Close door. Tools Needed: 3 1/2, 3/4 in ST-801 566-A 2-6. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- 1 ary support so cylinder cannot fall and break of
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2-7. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun 1 end through opening until it bottoms against drive assembly. Tighten nut. 4 Gun Trigger Plug Insert plug into receptacle, and 2 tighten threaded collar. 3 Close door. 4 Ref. ST-801 567 2-8. Setting Gun Polarity 1 Polarity Changeover Label Always read and follow manufac- ture’s recommended polarity. 1 Tools Needed: 3/4, 11/16 in Ref. 190 821-A OM-1313 Page 8
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2-9. Installing Wire Spool And Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. Tools Needed: When a slight force is needed 15/16 in to turn spool, tension is set. ST-072573-B 2-10. Changing Input Voltage Turn Off unit, and disconnect input power. Unit was shipped from factory set for 230 volts. 1 Transformer T1 2 Rear Of Power Switch S1 3 Lead Marked 230 Volt And Fan Motor Lead 2 Disconnect 230 volt lead and fan motor lead from rear of S1. Leave fan motor lead connecte
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2-11. Electrical Service Guide Input Voltage 200 230 Input Amperes At Rated Output 30 26 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 1 2 Circuit Breaker , Time-Delay 35 30 3 Normal Operating 45 40 Min Input Conductor Size In AWG/Kcmil 10 10 97 128 Max Recommended Input Conductor Length In Feet (Meters) (29) (39) Min Grounding Conductor Size In AWG/Kcmil 10 10 Reference: 1999 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to
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2-13. Threading Welding Wire Tools Needed: 4 in (102 mm) 6 in (150 mm) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Use pressure indicator Tighten scale to set a desired drive roll pressure. 1 Pressure 2 Indicator 3 Scale 4 Close and tighten pressure Remove gun nozzle and contact tip. Turn On. assembly, and let go of wire. Tighten 1 2 3 4 WOOD Press gun trigger until wire Feed wire to check drive roll pressure. Cut off wire. Cl
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Notes OM-1313 Page 12
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SECTION 3 – OPERATION 3-1. Front Panel Controls Controls For Standard Units 1 Wire Speed Control Use control to select a wire feed speed. Scale around control is not actual wire feed speed, but is for reference only. 2 Voltage Switch The higher the selected number, the thicker the material that can be welded (see Section 3-2). Do not switch while welding. 3 Power Switch 1 2 3 Ref. ST-180 930 OM-1313 Page 13
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3-2. Weld Parameter Chart *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. 240 Hotter Volts AC Lower Settings Use Parameter 230 Volts AC Chart Inside Door Weld Will Be Lower Colder e.g. 218 Volts AC Raise Settings OM-1313 Page 14
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Ref. 197 949 OM-1313 Page 15
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SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Maintain more often Disconnect power during severe conditions. before maintaining. 3 Months Clean And Repair Or Replace Tighten Replace Damaged Or Weld Cracked Unreadable Terminals Cables And Labels Cords 6 Months Remove drive roll Blow Out Or and apply light coat Vacuum Inside of oil or grease to drive motor shaft. 4-2. Circuit Breakers CB1 And CB2 2 1 Turn Off unit. 1 Circuit Breaker CB1 CB1 protects the transformer from
