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OM-193 471P
2006 −05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
R-115
File: MIG (GMAW)
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 Insta
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 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 necessa
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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 an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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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. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier d’É
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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SECTION 3 − INSTALLATION 3-1. 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) 75 to 750 ipm Width: 10-3/4 in Single Phase 100% (CV) DC And 40 lb (18 kg) (1.9 To 19 mpm) (273 mm) 2 Amperes 50/60 Duty Cycle Contactor Control Max Spool Weight: Hz Height: 11 in 60 lb (27 kg) (279 m
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3-3. Gun Recommendation Table Process Gun GMAW − Hard or Corded Wires M25 Or M40 FCAW − Self-Shielding Wires GA-40GL 3-4. Equipment Connection Diagrams 1 CV Welding Power Source With 115 VAC Power 2 Interconnecting Control Cord (Required) 3 Weld Cable (Required) 4 Work 1 2 4 3 3-5. Rear Panel Connections And Power Switch Location 1 Gas Hose With 5/8-18 Right- hand Thread Fittings (Customer Supplied) 3 Shielding gas pressure not to 2 exceed 100 PSI (689 kPa). 2 Strain Relief Install interconnec
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3-6. Connecting Welding Gun And Weld Cable 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. Tighten knob. 4 Gun Trigger Receptacle 1 2 5 Gun Trigger Plug 3 6 Weld Cable Terminal 7 Weld Cable From Welding Power Source 4 5 7 6 Tools Needed: 9/16 in 802 308 OM-193 471 Page 11
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3-7. Installing Wire Guide And Drive Roll 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. During maintenance intervals, remove drive rolls, and clean grooves using a wire brush. Check groove of drive roll for pitting or increase in the depth of the groove indicating drive roll is worn out. 1 3 2 Tools Needed: 3/8 in 802 310-A OM-193 471 Page 12
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3-8. Installing And Threading Welding Wire 1 Retaining Ring 2 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. 1 2 3 Reinstall retaining ring. Adjust tension nut so wire is taut when wire feed stops. 3 Pressure Assembly Adjustment Knob Lay gun cable out straight. A Open pressure assemblies, hold wire tightly, and cut off end. Push wire through guides into gun. B Close and tigh
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3-9. 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 5 the wire feeder is being con- nected to. 1 Strain Relief 2 Interconnecting Power Cord To ensure cord will be secure in 3 strain relief, slide supplied tub- ing over cord. Insert cord through strain relief. Ground lead must be wrapped 4 around ground current sensor to protect
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3-11. Connection For Hobart Welding Power Sources With 19-Socket Receptacle 1 Terminal Block 1T Make ground lead connections 2 Interconnecting Power Cord according to Section 3-9 before 3 Green Lead (Connected To following this procedure. Ground In Section 3-9) Connect remaining leads to terminal block as follows: A: 115 VAC/Neutral Lead B: 115 VAC/Hot Lead 3 C: No Connection E D: Dry Contact Closure w/Respect D C To Terminal E Lead B E: 115 VAC/Contact Closure Lead A For welding power sou
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3-13. Connection For Hobart Welding Power Sources With 5-Socket And 115 Volt AC Receptacles 1 Terminal Block 1T Make ground lead connections 2 3-Conductor Cord according to Section 3-9 before following this procedure. 3 2-Conductor Cord 4 Green Lead (Connected To Ground In Section 3-9) 1 Connect remaining leads to terminal block as follows: A: 115 VAC/Neutral Lead E B: 115 VAC/Hot Lead D C: No Connection C 3 B A D: Dry Contact Closure w/Respect To Terminal E Lead E E: 115 VAC/Contact Closur
