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Miller Electric OM-1313 manual

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Table of contents for the manual

  • Page 1

    Processes Description MIG (GMA W) W elding Flux Cored (FCA W) W elding Arc Welding Power Source And Wire Feeder OM-1313 179 084P September 2001 Millermatic 185 And M-15 Gun R Visit our website at www.MillerWelds.com[...]

  • 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

    The following terms are used interchangeably throughout this manual: MIG = GMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-1313 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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! W atch[...]

  • Page 6

    OM-1313 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-1313 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-1313 Page 4 1-5. EMF Information Considerations About W elding And The Effects 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-1313 Page 5 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 Output, 60 Hz, Single-Phase W eight Overall Dimensions V oltage DC 200 V 230 V KV A KW 150 A @ 23 V olts DC, 60% Duty Cycle 30 – 185 33 30 (1.6)* 26 (1.4)* 6 (0.27)* 5 (0.13)* 165 lb (75[...]

  • Page 10

    OM-1313 Page 6 6 Minutes W elding 4 Minutes Resting 2-3. W elding Power Source Duty Cycle And Overheating Duty Cycle is percentage of 10 mi n - 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 d[...]

  • Page 11

    OM-1313 Page 7 2-5. Installing Work Clamp 1 W ork Cable 2 Boot Slide boot onto work cable. Route cable out front panel opening from inside. 3 Negative ( – ) Output T erminal Connect cable to terminal and cover connection with boot. 4 Hardware 5 W ork Clamp Route cable through clamp handle and secure as shown. Close door . ST-801 566-A 1/2, 3/4 in[...]

  • Page 12

    OM-1313 Page 8 2-7. Installing Welding Gun Ref. ST-801 567 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun en d through opening until it bottoms against drive assembly . T ighten nut. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar . Close door . 2 1 3 4 2-8. Setting Gun Polarity 1 Polarit[...]

  • Page 13

    OM-1313 Page 9 2-9. Installing Wire Spool And Adjusting Hub T ension ST-072573-B When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with 8 in (200 mm) spools. T ools Needed: 2-10. Changing Input V oltage ST-801 580-A Y T ur n Off unit, and disconnect input power . Unit was shipped from factory set for 230 v[...]

  • Page 14

    OM-1313 Page 10 2-1 1. Electrical Service Guide Input V oltage 200 230 Input Amperes At Rated Output 30 26 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1 , Time-Delay 2 35 30 Normal Operating 3 45 40 Min Input Conductor Size In A WG/Kcmil 10 10 Max Recommended Input Conductor Length In Feet (Meters) 97 (29) 128[...]

  • Page 15

    OM-1313 Page 1 1 2-13. Threading Welding Wire Ref. ST-801 570-A / ST -801 083 / S-0627-A 6 in (150 mm) 4 in (102 mm) WOOD Open pressure assembly . Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Close and tighten pressure assembly , and let go of wire. Remove gun nozzle and contact tip. T urn On. Press gun tr[...]

  • Page 16

    OM-1313 Page 12 Notes[...]

  • Page 17

    OM-1313 Page 13 SECTION 3 – OPERA TION 3-1. Front Panel Controls Ref. ST-180 930 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 V oltage Switch The higher the selected number , the thicker the material that can be welded (s[...]

  • Page 18

    OM-1313 Page 14 3-2. W eld Parameter Chart Input Line Voltage* Parameter Chart Settings Higher e.g. 240 Volts AC 230 Volts AC Lower e.g. 218 Volts AC Weld Will Be Hotter Lower Settings Use Parameter Chart Inside Door Weld Will Be Colder Raise Settings *Line voltage can af fect weld output, settings on this chart are starting values only . Y ou may [...]

  • Page 19

    OM-1313 Page 15 Ref. 197 949[...]

  • Page 20

    OM-1313 Page 16 SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine 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 T erminals Repair Or Replace Cracked Cables And Cords 6 Months Blow Out Or V acuum Inside Remove drive [...]

  • Page 21

    OM-1313 Page 17 4-4. Cleaning Or Replacing Gun Liner Ref. ST-800 797-C 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 22

    OM-1313 Page 18 4-5. Replacing Switch And/Or Head T ube Ref. ST-800 795-C 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 handle, and secure with handle locking nut. If replacing head tube, continue to[...]

  • Page 23

    OM-1313 Page 19 4-6. Replacing Gun Contact Tip Ref. 800 797-C Y T urn Off unit. 1 Nozzle 2 Contact T ip 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: 4-7. T roubleshooting W elding T rouble Remedy No weld output; wire does not feed. Secure power cord plug in[...]

  • Page 24

    OM-1313 Page 20 SECTION 5 – ELECTRICAL DIAGRAM SB-186 065 Figure 5-1. Circuit Diagram[...]

  • Page 25

    OM-1313 Page 21 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 or k c l a m p a s close t o the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Shieldi[...]

  • Page 26

    OM-1313 Page 22 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 27

    OM-1313 Page 23 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 28

    OM-1313 Page 24 6-4. Conditions That Affect W eld 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 Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PRO[...]

  • Page 29

    OM-1313 Page 25 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 W eave Bead – Side T o Side Movement Alon[...]

  • Page 30

    OM-1313 Page 26 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 31

    OM-1313 Page 27 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 32

    OM-1313 Page 28 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 33

    OM-1313 Page 29 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 34

    OM-1313 Page 30 Problem Remedy Probable Cause W elding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary . W rong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed o n welding power sou[...]

  • Page 35

    OM-1313 Page 31 Notes[...]

  • Page 36

    OM-1313 Page 32 SECTION 7 – P ARTS LIST 801 572-C . Hardware is common and not available unless listed. 31 29 28 35 9 34 33 36 25 27 26 32 23 24 22 1 2 4 (Fig.7 – 2) + – 3 5 21 17 18 16 20 19 10 15 8 9 14 13 12 6 7 11 30 Figure 7-1. Main Assembly[...]

  • Page 37

    OM-1313 Page 33 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Quantity 1 151 187 LA TCH, slide flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 134 464 LABEL, warning general precautionary 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 38

    OM-1313 Page 34 Figure 7-2. Center Baffle w/Components ST-801 631-D . Hardware is common and not available unless listed.[...]

  • Page 39

    OM-1313 Page 35 Description Part No. Item No. Figure 7-2. Baffle, Center w/Components (Fig 7-1 Item 4) Quantity Dia. Mkgs. 1 058 427 RING, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 085 980 NUT , 625-1 1 .94 hex 1 . . . . . . . . . . . . . . . . . .[...]

  • Page 40

    OM-1313 Page 36 Description Quantity Part No. 169 589 Item No. Figure 7-3. M-15 Gun (Fig 7-1 Item 36) 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 087 299 TIP , contact scr .023 wire x 1.125 . . . . . . . . 2 ♦ 000 067 TIP , contact scr[...]

  • Page 41

    OM-1313 Page 37 Description Part No. Item No. Figure 7-4. Drive Assembly , Wire (Fig 7-2 Item 29) Quantity 1 196 237 MOTOR, gear 24VDC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 180 929 HOUSING, motor drive 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 42

    [...]

  • Page 43

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y o ur 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 [...]

  • Page 44

    PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada F AX : 920-735-4134 Int ernati onal FAX: 920-735-4125 European He adquarte rs – Unite[...]