OM-1213 137 531AG 2010−04 Processes MIG (GMAW) Welding Description Feeder Gun Spoolmatic 15A And 30A R File: MIG (GMAW) Visit our website at www.MillerWelds.
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TABLE OF CONTENTS SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 −SAFETY PRECAUTIONS FOR GMAW WELDING GUNS − READ BEFORE USING SR7 (MIG) 2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
1-3. Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-4.
SECTION 2 − MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW − À LIRE AVANT UTILISATION SR7(MIG)_2010−03fre Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
Le BRUIT peut endommager l’ouie. LIRE LES INSTRUCTIONS. D Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. D N’utiliser que les pièces de rechange recommandées par le constructeur. D Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux.
SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions U1 IP V U2 Primary Voltage Degree Of Protection Volts Conventional Load Voltage I1 I2 A X Primary Current Rated Welding Current Amperes Duty Cycle Percent SECTION 4 − INSTALLATION 4-1. Specifications Wire Diameter Range .025 Thru 1/16 in. (0.6 Thru 1.6 mm) Aluminum Wire .025 Thru .045 in. (0.6 Thru 1.1 mm) Hard Or Cored Wire Approximate Wire Feed Range 70 To 875 ipm (1.7 To 22.2 mpm) Cooling Method Air Cooled Maximum Spool Size 4 in.
4-3. Installing Wire Spool And Threading Welding Wire 1 2 3 4 8 Top Cover Canister Canister Cover Thumbscrew (Canister Cover) Loosen thumbscrew and remove cover. 7 5 Wire Spool Loosen wire from spool, cut off bent wire, and pull 6 in. (150 mm) of wire off spool. 6 Pressure Roll Assembly Lift arm and open pressure roll assembly. 7 8 6 Canister Inlet Guide Drive Roll Groove . For wire sizes .035 in. (0.9 mm) and smaller use small groove, and .047 in. (1.2 mm) and 1/16 in (1.6 mm) use large groove.
4-5. Connecting To 24 Volt Weld Control 1 Gas Hose Connect fitting to regulator/flowmeter (see Section 4-7). 1 4 3 2 2 3 24 Volt Weld Control Trigger Control Cord Insert plug into receptacle, and tighten threaded collar. 4 Weld Cable Connect to positive (+) weld output terminal on welding power source according to its Owner’s Manual. Tools Needed: 1-1/8, 5/8 in. 150 917-G 4-6. Connecting To 115 Volt Weld Control 1 2 115 Volt Weld Control Gas Hose Connect to regulator/flowmeter.
4-7. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 2 Cap Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 4 Cylinder Regulator/Flowmeter Install so face is vertical. 1 5 Gas Hose Connection Fitting has threads. 6 5/8-18 right-hand Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour).
4-8. Adjusting Drive Roll And Spool Brake Pressure 1 2 3 Top Cover Canister Cover Thumbscrew Loosen thumbscrew and remove cover. 4 Spool Cut welding wire off at contact tip. Retract wire onto spool and secure. 5 5 1 Spool Brake Thumbnut Grasp spool in one hand and turn while adjusting spool brake thumbnut. When a slight force is needed to turn spool, tension is set. Do not overtighten. 2 3 Reinstall canister cover. Thread welding wire (see Section 4-3).
SECTION 5 − OPERATION 5-1. Controls 1 Trigger Press trigger to energize welding power source contactor (if applicable), start shielding gas flow, and begin wire feed. For shielding gas preflow and postflow, lightly press trigger before and after welding. 2 Wire Speed Control Use control to adjust wire feed speed. The numbers in the opening are not a wire feed speed and are for reference only. 1 2 Ref. 147 741-F 5-2.
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! . Maintain more often Disconnect power before maintaining. during severe conditions. 3 Months Replace Damaged Or Unreadable Labels Clean And Tighten Weld Terminals Replace Damage Gas Hose Repair Or Replace Cracked Cables And Cords 6 Months Blow Out Or Vacuum Inside Clean Drive Rolls 6-2. Changing Gun Contact Tip Remove nozzle 1 Nozzle 2 FasTip Unscrew FasTip. Install new FasTip. 2 1 Ref.
6-3. Replacing Head Tube Liner The standard head tube liner will accommodate wire diameters from .030-1/16 wire size. 1 2 3 5 Cover Screw Clamp Loosen clamp screws and remove clamp. 4 Head Tube Remove head tube from gun. 4 2 3 1 4 5 Liner Pull liner out of head tube. Insert liner into head tube and reinstall head tube onto gun. . A twisting motion may be need- ed to feed liner thru head tube. Tool Needed: 5/32 in. Ref.
6-4. Gun Drive Assembly Maintenance Retract wire onto spool. 1 2 This tab helps prevent burnback caused by welding arcs inside the contact tip. This tab may be removed to provide an insulated drive roll. (If tab is removed, a smaller diameter contact tip is recommended. See options in Parts List.) Lightly grease top of tab before reinstalling. 3 3 1 Setscrew Current Pick-Up Tab Drive Roll Use wire brush to clean drive roll.
6-5. Replacing Canister Inlet Guide 1 2 Top Cover Pressure Roll Assembly Cut off welding wire where it enters pressure roll assembly area. 3 1 7 Nozzle Pull wire out nozzle. 6 5 2 4 4 5 Thumbscrew Canister Cover Loosen thumbscrew and remove cover. 6 7 Wire Spool Spool Brake Thumbnut Loosen thumbnut, retract wire onto spool, secure, and remove spool. 8 3 Canister Inlet Guide Turn counterclockwise to remove. Install new guide. Reinstall spool and thread welding wire (see Section 4-3).
6-7. Replacing Diffuser Turn Off welding power source. 1 Nozzle 2 FasTip To remove, see Section 6-2. 3 Diffuser Remove diffuser and replace. 3 2 1 Tools Needed: 3/8 in. Ref. 803 348-G 6-8. Troubleshooting Trouble Remedy No weld output; gun/feeder does not Secure weld control plug in 115 volts AC receptacle (see weld control Owner’s Manual). work. Place Power switch on welding power source in the On position (see welding power source Owner’s Manual). Erratic weld output.
SECTION 7 − ELECTRICAL DIAGRAM 195 712-B Figure 7-1.
Notes OM-1213 Page 17
OM-1213 Page 18 Figure 8-1. Complete Assembly 18 13 19 20 21 12 10 11 9 6 22 23 17 24 69 25 29 8 26 27 28 64** 30 31 32 63 33 65 36 33 34 35 37 62 61 60 43 42 39 59 46 68 67 56 58 57 40 44 41 38 45 55 47 48 13 49 50 51 52 54 53 not available unless listed. 7 3 5 . Hardware is common and 14 15 66 1 4 SECTION 8 − PARTS LIST Ref.
Item No. Dia. Mkgs. Part No. Description Quantity Model 15A 30A Figure 8-1. Complete Assembly . . . 1 . . . . . . . . . . . . . 214 745 . . Cover (Included With Item 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . 2 . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . 133 362 . . Strain Relief, Cable . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Complete Assembly (Continued) . . . 46 . . . . . . . . . . . . . 602 154 . . Screw, .250-20 X .500Hexhd Stl Slffmg . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . 47 . . . . . . . . . . . . . 132 527 . . Canister, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . 48 . . . . . . . . . . . . . 148 488 . . Post, Support Spool . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST INCLUDING CONSUMABLES Item Number 1 2 3 4 5 .030−1/16” WIRE STANDARD INSULATOR .030−1/16” WIRE .035−1/16” WIRE .030−1/16” WIRE (231 512) COLLARED INSULATOR (227 749) (#232 284) XR-A Spoolmatic Barrel Assy 6.0” STRAIGHT (#221 087) (231 511) TAPERED INSULATOR Ref. 803 909-A / 803 932 / 803 933 / 803 934 Figure 9-1.
Item No. Part No. Description Quantity Figure 9-1. Consumables Flowchart Table 9-1. Nozzles . . . 1 . . . . . . . . . ♦176238 . . Nozzle, Spot Flat (Requires Diffuser 209099, Used With Any Heavy Duty FasTipt Contact Tip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . ♦176240 . . Nozzle, Spot Inside Corner (Requires Diffuser 209099, Used With Any Heavy Duty FasTipt Contact Tip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Part No. Description Quantity Figure 9-1. Consumables Flowchart (Continued) Table 9-5. Value Multi−Turn Contact Tips* ... ... ... ... ... ... ... 2 2 2 2 2 2 2 ........ ........ ........ ........ ........ ........ ........ ♦071 825 ♦054 202 ♦054 201 ♦199 593 ♦044 006 ♦047 566 ♦202 933 .. .. .. .. .. .. .. .030 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .035 in (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . .
Notes SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) Specifications Socket or Wrench Size SOCKET/WRENCH SELECTION TABLE (METRIC) Specifications Socket or Wrench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in. .250 in. 3/8 in. 7/16 in. 6 mm .2362 in. 10 mm 10 mm 5/16 in. .3125 in. 1/2 in. 9/16 in. 8 mm .3150 in. 14 mm 14 mm 3/8 in. .375 in. 9/16 in. 5/8 in. 10 mm .3937 in. 17 mm 17 mm 7/16 in. .4375 in. 5/8 in.
Notes
Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (.031 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 16 Gauge (.063 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in. (.313 in.) 3/8 in. (.375 in.) 1/2 in. (.5 in.
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