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Manual Miller Electric R-115

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  • Miller Electric R-115 - page 1

    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.com File: MIG (GMA W) ...

  • Miller Electric R-115 - 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 specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille ...

  • Miller Electric R-115 - page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . ...

  • Miller Electric R-115 - page 4

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  • Miller Electric R-115 - page 5

    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. Y Marks a special safety m ...

  • Miller Electric R-115 - page 6

    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. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching ...

  • Miller Electric R-115 - page 7

    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. ...

  • Miller Electric R-115 - page 8

    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 .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W elding Society Standard A ...

  • Miller Electric R-115 - page 9

    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. 2-1. Symbo les util isés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es risques poss ibl ...

  • Miller Electric R-115 - page 10

    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. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe ...

  • Miller Electric R-115 - page 11

    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. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharge ...

  • Miller Electric R-115 - page 12

    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 .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el ...

  • Miller Electric R-115 - page 13

    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 (1.9 T o 19 mpm) .030 T o 3/32 ...

  • Miller Electric R-115 - page 14

    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. Equipment Connection Diagrams 4 3 2 1 1 Gas Hose With 5/8-18 Right- hand Thread F ...

  • Miller Electric R-115 - page 15

    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. Connecting Welding Gun And W e ...

  • Miller Electric R-115 - page 16

    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. During maintenance intervals, remove drive rolls, and clean grooves using a wire brush. Check gr ...

  • Miller Electric R-115 - page 17

    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. Reinstall retaining ring. Adjust tension nut so wire is taut when wire feed stops. ...

  • Miller Electric R-115 - page 18

    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. 1 Strain Relief 2 Interconnecting Power Cord . T o ensure ...

  • Miller Electric R-115 - page 19

    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 o Ground In Section 3-9) Connect remaining leads to terminal block as follows: A: 1 15 V AC/Neutral Lead B: 1 15 V AC/Hot Lead C: No Connection D: Dry ...

  • Miller Electric R-115 - page 20

    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 4 Green Lead (Connected T o Ground In Section 3-9) Connect remaining leads to terminal block as follows: A: 1 15 V AC/Neutral Lead B: 1 15 V AC/Hot Le ...

  • Miller Electric R-115 - page 21

    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 (Connected T o Ground In Section 3-9) Connect remaining leads to terminal block as follows: A: 1 15 V AC/Neutral Lead B: 1 15 V AC/Hot Lead C: No Connectio ...

  • Miller Electric R-115 - page 22

    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 In Section 3-9) Connect remaining leads to terminal block as follows: A: 1 15 V AC/Neutral Lead B: 1 15 V AC/Hot Lead C: No Connection D: No Connecti ...

  • Miller Electric R-115 - page 23

    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. Adjust potentiometer R73 using a small n ...

  • Miller Electric R-115 - page 24

    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. Use Purge position to momentarily energize gas valve to purge air from gun or adjust gas regulat ...

  • Miller Electric R-115 - page 25

    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 erminals Repair Or Replace Cracked Weld Cable Gas Hose Gun Cable Replace Cracked Parts 6 Months Blow Out Or V acuum Inside, During Heavy Service, Clean Month ...

  • Miller Electric R-115 - page 26

    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 . Wire does not feed. Check circuit breaker CB1 (see Section 5-2). Check gun trigger conne ...

  • Miller Electric R-115 - page 27

    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 ...

  • Miller Electric R-115 - page 28

    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. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Quantity 1 089 899 LA TCH 1 . . . . ...

  • Miller Electric R-115 - page 29

    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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 GS1 228 036 V AL VE, 24V AC 1way .750 − 14 thd 2mm orf 100PSI 1 . . . . . . . . . . . ...

  • Miller Electric R-115 - page 30

    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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 CARRIER, drive roll w/component 24 pitch 4 . . . . . . . . . . . . . . . . . ...

  • Miller Electric R-115 - page 31

    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). 4. V -Knurled rolls for hard shelled core ...

  • Miller Electric R-115 - page 32

    OM-193 471 Page 28 Notes ...

  • Miller Electric R-115 - page 33

    OM-193 471 Page 29 Notes ...

  • Miller Electric R-115 - page 34

    OM-193 471 Page 30 Notes ...

  • Miller Electric R-115 - page 35

    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. Support Need fast answers to the tough welding questions? Contact your distributor . The expe ...

  • Miller Electric R-115 - page 36

    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 − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX: 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − U ...

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A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Miller Electric R-115 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Miller Electric R-115.

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2. Contents - index of all tips concerning the Miller Electric R-115, that we can find in the current document
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5. FAQ - Frequently Asked Questions
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