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Miller Electric M-15 manual

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Table of contents for the manual

  • Page 1

    Millermatic Challenger And M-15 Gun R Visit our website at www.MillerWelds.com Arc Welding Power Source And Wire Feeder Processes Description MIG (GMA W) W elding Flux Cored (FCA W) W elding OM-1314 180 846A February 1997[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    [...]

  • Page 5

    OM-1314 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Watch [...]

  • Page 6

    OM-1314 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D 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 Z8[...]

  • Page 7

    OM-1314 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. F [...]

  • Page 8

    OM-1314 Page 4 1-5. EMF Information Considerations About W elding And The Ef fects Of Low Frequency Electric A n d M a g netic Fields W elding 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 years[...]

  • Page 9

    OM-1314 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulier .[...]

  • Page 10

    OM-1314 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans l[...]

  • Page 11

    OM-1314 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharger [...]

  • Page 12

    OM-1314 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for th[...]

  • Page 13

    OM-1314 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications Rated W elding Output Amperage Range Maximum Open-Circuit V oltage DC Amperes Input at Rated Load Out- put 230 V , 60 Hz, Single-Phase KV A KW W eight Overall Dimensions 130 A @ 20.5 V olts DC, 30% Duty Cycle 40 – 170 33 20.5 (0.27)* 4.7 (.05)* 4 (.04)* 95 lb (43.1 kg) Length: 17 in [...]

  • Page 14

    OM-1314 Page 10 2-3. Duty Cycle And Overheating 3 Minutes W elding 7 Minutes Resting Duty Cycle is percentage of 10 m in - 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 duty cycle before welding. Y Excee[...]

  • Page 15

    OM-1314 Page 1 1 2-4. Installing Work Clamp 1 Insulator 2 Bolt 3 Smaller Hole 4 W ork Clamp T ab s Bend tabs around work cable. 5 W ork Cable From Unit 6 Nut Ref. ST-025 190-D 1 2 3 4 5 6 3/8, 7/16 in T ools Needed: 2-5. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other station- ary support so cylinder cannot fall[...]

  • Page 16

    OM-1314 Page 12 2-6. Installing W elding Gun And Setting Gun Polarity For Wire T ype 1 Gun Opening 2 Gun Trigger Receptacle 3 Gun Securing Nut 4 Drive Assembly 5 Gun End Loosen securing nut. Insert gun en d through opening until it bottoms against drive assembly . Tighten nut. 6 Gun Trigger Plug Insert plug into receptacle, and tighten threaded col[...]

  • Page 17

    OM-1314 Page 13 2-7. Electrical Service Guide Input V oltage 230 Input Amperes At Rated Output 20.5 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 25 Min Input Conductor Size In A WG/Kcmil 14 Max Recommended Input Conductor Length In Feet (Meters) 64 (19) Min Grounding Conductor Size In A WG/Kcmil 14 Reference: 1996 National Ele[...]

  • Page 18

    OM-1314 Page 14 2-9. Installing Wire Spool And Adjusting Hub T ension S-0499 15/16 in Standard Wire Spool 1 Lb Wire Spool When a slight force is needed to turn spool, tension is set. T ools Needed: Standard Wire Reel Part No. 183 312 Part No. 135 615[...]

  • Page 19

    OM-1314 Page 15 2-10. Installing Drive Roll And Threading Welding Wire Ref. ST-149 266-B / Ref. ST -149 326-B / Ref. 150 093-A / Ref. 180 968 / S-0627-A Install drive roll onto shaft with de- sired groove in, and one set screw facing flat side of shaft. T ighten both set screws. For Solid Wire For Flux Cored Wire WOOD 1 Install drive roll. 2 Open p[...]

  • Page 20

    OM-1314 Page 16 2-1 1. Weld Parameters Wire T ype, Wire Material Thickness Wire T ype, Shielding Gas, And Flow Rate Wire Diameter (inch) Operator Controls 1/4 in. (6.4 mm) 3/16 in. (4.8 mm) 1/8 in. (3.2 mm) 14 ga. 16 ga. 18 ga. 20 ga. 22 ga. V oltage T a p – – 5 4 3 3 2 2 1 .023 Wire Speed – – 70 60 50 30 20 5 0 E70S-6 V oltage T a p 6 5 4 [...]

  • Page 21

    OM-1314 Page 17 SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace Damaged Or Unreadable Labels Clean And T ighten W eld Connections Repair Or Replace Cracked Cables And Cords 6 Months Blow Out Or V acuum Inside stat_maint – 2/96 [...]

  • Page 22

    OM-1314 Page 18 4-4. Replacing Gun Contact Tip ST-149 326-B Y T urn Off power before replacing contact tip. 1 Nozzle 2 Contact Tip Cut of f welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. 1 2 T ools Needed: 4-5. Unicable Repair T o repair or replace unicable, order Unicable Clamp Kit, pa[...]

  • Page 23

    OM-1314 Page 19 4-6. Cleaning Or Replacing Gun Liner Ref. ST-800 797-A 3/8 i n T o Reassemble Gun: Insert new liner . Install and tighten wire outlet guide. Cut liner off 3/4 in (20 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter , contact tip, and nozzle. Lay gun cable out straight before installing new liner . Head Tube 3/8 in [...]

  • Page 24

    OM-1314 Page 20 4-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-A Do not disturb cable connection between cable connector and connector nut. 1 Remove handle locking nut. 2 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 hand[...]

  • Page 25

    OM-1314 Page 21 4-8. Cleaning Or Repairing Drive Assembly Ref. ST-150 093-A / ST -149 266-B Y T urn Off power before cleaning or repairing drive assembly . 1 Wire Spool 2 Nozzle Cut welding wire of f at nozzle. Retract wire onto spool and secure. 3 Pressure Roll Arm 4 Cotter Pin 5 Pin 6 Screw 7 Bearing Remove bearing. Install new bear- in g and sec[...]

  • Page 26

    OM-1314 Page 22 4-9. T roubleshooting W elding T rouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-8). Check and replace power switch if necessary . Check fuse F1, and replace if necessary (see Section 4-2). Replace building line fuse or reset circuit breaker if open (see Section 2-8). Secure gun [...]

  • Page 27

    OM-1314 Page 23 SECTION 5 – ELECTRICAL DIAGRAM SB-180 784-B Figure 5-1. Circuit Diagram[...]

  • Page 28

    OM-1314 Page 24 SECTION 6 – MIG WELDING (GMA W) GUIDELINES 6-1. T ypical MIG Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla c e w o r k c l a m p a s close to the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Shieldi[...]

  • Page 29

    OM-1314 Page 25 6-2. T ypical MIG Process Control Settings These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. NOTE 1/8 or .125 in Material thickness determines weld parameters. Convert Material (.001 in = 1 ampere) .12[...]

  • Page 30

    OM-1314 Page 26 6-3. Holding And Positioning Welding Gun 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. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 Electrode[...]

  • Page 31

    OM-1314 Page 27 6-4. Conditions That Affect Weld Bead Shape 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. NOTE Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS (STICKO[...]

  • Page 32

    OM-1314 Page 28 6-5. Gun Movement During Welding 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 . NOTE 1 Stringer Bead – Steady Movement Along Seam 2 Weave Bead – Side T o Side Movement Along[...]

  • Page 33

    OM-1314 Page 29 6-8. T roubleshooting – Excessive Spatter Excessive Spatter – scattering of molten metal particles that cool t o solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use [...]

  • Page 34

    OM-1314 Page 30 6-1 1. T roubleshooting – 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 maintainin[...]

  • Page 35

    OM-1314 Page 31 6-14. T roubleshooting – W aviness Of Bead W aviness O f Bead – weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support hand[...]

  • Page 36

    OM-1314 Page 32 6-16. 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. Application Gas Spray Arc Steel Short Circuiting Steel Short Circui[...]

  • Page 37

    OM-1314 Page 33 Notes[...]

  • Page 38

    OM-1314 Page 34 SECTION 7 – P ARTS LIST 1 Fig 7-3 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 23 24 25 26 22 19 20 18 21 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Fig 7-2 44 45 46 50 49 ST-801 633 47 48 . Hardware is common and not available unless listed. Figure 7-1. Main Assembly[...]

  • Page 39

    OM-1314 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Quantity 1 131 315 DRIVE ASSEMBL Y , wire (Fig 7-3) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 909 NUT , 375-16 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 40

    OM-1314 Page 36 1 ST-801 140 23 4 5 6 7 6 8 9 10 11 13 16 24 17 28 18 19 14 18 19 17 16 11 10 9 8 23 25 27 12* *Includes Item 17 15 26 22 20 21 Figure 7-2. M-15 Gun . Hardware is common and not available unless listed.[...]

  • Page 41

    OM-1314 Page 37 Quantity Description Part No. 169 589 Item No. Figure 7-2. M-15 Gun (Fig 7-1 Item 43) 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 176 237 NOZZLE, spot flat 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 42

    OM-1314 Page 38 Description Quantity Part No. Dia. Mkgs. Item No. Figure 7-3. Drive Assembly , Wire (Fig 7-1 Item 1) 1 MOT 173 446 MOTOR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 129 893 INSULA TOR, housing drive 1 . . . . . . . . . . . . . . . . . .[...]

  • Page 43

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 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. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 44

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool W orks Company 1635 W est S pencer Street Applet on, W I 5 4914 USA International He adquarters – US A USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F AX : 920-735-4134 Int ernational F AX: 920-735-4125 European Headqua rters – Uni[...]