Miller Electric Millermatic 155 And M-15 Gun User manual

OWNER’S
MANUAL
June 1996 Form: OM-1314
Effective With Serial No. KG171523
cover_om 4/95 −ST-800 091-C PRINTED IN USA
©1996 MILLER Electric Mfg. Co.
Millermatic®155 And M-15 Gun
230 Volt Wire Welder
Rated Welding
Output Amperage
Range
Maximum
Open-Circuit
Voltage DC
Amperes Input at
Rated Load Out-
put 115 V, 60 Hz,
Single-Phase
KVA KW Weight Overall
Dimensions
130 A @ 20.5 Volts
DC, 30% Duty Cycle 40 −170 33 20.5
(0.27)*
4.7
(.05)*
4
(.04)* 80 lb
(36.3 kg)
Length: 17 in
(432 mm)
Width: 10 in
(254 mm)
Height: 15-1/2 in
(394 mm)
Wire Type
And Dia
Solid/
Stainless Flux Cored/ Aluminum Calculated Wire Speed Range At
No Load Max Wire Feed Speed While Welding
And Dia
.023 −.035 in
(0.6 −0.9 mm) .030 −.045 in (0.8 −1.1 mm) 126 −722 IPM (3.2 −18.3 m/min) 500 IPM (12.7 m/min)
* While idling

OM-1314 Page 5
SECTION 1 −INSTALLATION
1-1. Installing Work Clamp
1 Insulator
2 Bolt
3 Smaller Hole
4 Work Clamp Tabs
Bend tabs around work cable.
5 Work Cable From Unit
6 Nut
Ref. ST-025 190-D
1
2
3
4
5
6
3/8, 7/16 in
Tools Needed:
1-2. Installing Welding Gun And Setting Gun Polarity For Wire Type
1 Gun Opening
2 Gun Trigger Receptacle
3 Gun Securing Nut
4 Drive Assembly
5 Gun End
Loosen securing nut. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
nut.
6 Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
Close door.
1
2
3
4
56
ST-149 328-B / Ref. ST-159 270
5/16 in
Front Panel Openings
Straight Polarity
DCEN Reverse Polarity DCEP
Flux Cored Wires
(FCAW−Without Gas)
Solid Steel Or
Aluminum Wires
(GMAW−With Gas)
.Follow wire manufacturer’s recommendation.
Tools Needed:

OM-1314 Page 6
1-3. Electrical Service Guide
Input Voltage 230
Input Amperes At Rated Output 20.5
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 25
Min Input Conductor Size In AWG/Kcmil 14
Max Recommended Input Conductor Length In Feet (Meters) 64 (19)
Min Grounding Conductor Size In AWG/Kcmil 14
Reference: 1996 National Electrical Code (NEC) S-0092-J
1-4. Selecting A Location And Connecting Input Power
1 Rating Label
Supply correct input power.
2 Plug
3 Receptacle
Connect plug to receptacle.
4 Line Disconnect Device
See Section 1-3.
YSpecial installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
ssb2.2* 1/94 −ST-801 504
1
18 in (457 mm) of
space for airflow
L1
L2
L1
L2
2
230 VAC, 1
YAlways connect
grounding
conductor first.
= GND/PE
4
3
YDo not move or operate unit
where it could tip.

OM-1314 Page 7
1-5. Installing Wire Spool And Adjusting Hub Tension
S-0499
15/16 in
Standard Wire Spool 1 Lb Wire Spool
When a slight force is needed
to turn spool, tension is set.
Tools Needed:

OM-1314 Page 8
1-6. 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. Tighten both
set screws.
For Solid Wire
For Flux Cored Wire
WOOD
6 in
(150 mm)
1 Install drive roll.
2 Open pressure assembly. 3 Pull and hold wire; cut off end.
4 Push wire thru guides into gun;
continue to hold wire.
5 Close and tighten pressure assembly,
and let go of wire. 6 Remove gun nozzle and contact tip.
7 Turn power On. 8 Press gun trigger until wire comes out
of gun.
9 Reinstall contact tip and nozzle. 10 Feed wire to check drive roll
pressure. Tighten knob enough to
prevent slipping. Cut off wire; leave
1/4−1/2 in (6−13 mm). Close and
latch door.
Tools Needed:

OM-1314 Page 9
SECTION 2 −OPERATION
2-1. Controls
Ref. ST-180 968
1 Wire Speed Control
Use control to select a wire feed
speed. As Voltage switch setting in-
creases, wire speed range also in-
creases.
2 Voltage Switch
The higher the selected number,
the thicker the material that can be
welded. Do not switch while
welding.
3 Power Switch
2
3
1

OM-1314 Page 10
NOTES

OM-1314 Page 11
2-2. Duty Cycle And Overheating
3 Minutes Welding 7 Minutes Resting
Duty Cycle is percentage of 10 min-
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.
YExceeding duty cycle can
damage unit or gun and void
warranty.
Overheating
0
15
A or V
OR
Reduce Duty Cycle
Minutes
duty1 4/95 −SB-180 844
30% Duty Cycle At 130 Amperes
300
250
200
150
100
75
50
10 15 20 25 30 40 50 60 70 80 100
DC AMPERES
% DUTY CYCLE

OM-1314 Page 12
SECTION 3 −MAINTENANCE & TROUBLESHOOTING
3-1. Maintenance
YDisconnect power
before maintaining. .Maintain more often
during severe conditions.
3 Months
Replace
Damaged Or
Unreadable
Labels
Clean And
Tighten
Weld
Connections
Repair Or
Replace
Cracked
Cables
And Cords
6 Months
Blow Out Or
Vacuum Inside
stat_maint −2/96
3-2. Fuse F1
Ref. ST-801 552
YTurn Off unit, disconnect in-
put power. Unlatch door and
remove wrapper.
1 Circuit Board PC1
2 Fuse F1 (See Parts List For
Rating)
If F1 opens, wire drive motor shuts
down. Replace F1 if open.
Reinstall wrapper, and latch door.
3/8 in
1
2
Tools Needed:
3-3. Short Circuit Shutdown
If contact tip is shorted and sticks to workpiece, the unit shuts down, but fan runs. To resume operation, release gun
trigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn On unit to
continue operation.