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OM-1213137 531AN2015 11ProcessesMIG (GMAW) WeldingDescriptionFeeder GunRSpoolmatic 15AAnd 30AFile: MIG (GMAW)Visit our website atwww.MillerWelds.com
From Miller to YouThank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you don’t have time to doit any other way.That’s why when Niels Miller first started building arc welders in 1929,he made sure his products offered long-lasting value and superiorquality. Like you, his customers couldn’t afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.Today, the people that build and sell Miller products continue thetradition. They’re just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.This Owner’s Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.We’ve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,there’s a Troubleshooting section that willhelp you figure out what the problem is. TheMiller is the first welding parts list will then help you to decide theequipment manufacturer in exact part you may need to fix the problem.the U.S.A. to be registered tothe ISO 9001 Quality System Warranty and service information for yourStandard.particular model are also provided.Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.Mil Thank 2009 09Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.
TABLE OF CONTENTSSECTION 1 SAFETY PRECAUTIONS FOR GMAW WELDING GUNS READ BEFORE USING . . . . . .11-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3. Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2SECTION 2 MESURES DE SÉCURITÉ VISANT LES PISTOLETS DE SOUDAGE GMAW À LIRE AVANTUTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42-5. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4SECTION 3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5SECTION 4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64-1. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64-2. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6SECTION 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-1. Removing Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65-2. Installing Wire Spool And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75-3. Rotating Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75-4. Connecting To 24 Volt Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85-5. Connecting To 115 Volt Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85-6. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95-7. Adjusting Drive Roll And Spool Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10SECTION 6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116-2. Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11SECTION 7 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127-1. Changing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127-2. Replacing Head Tube Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137-3. Gun Drive Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147-4. Replacing Canister Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157-5. Replacing Spool Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157-6. Replacing Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167-7. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16SECTION 8 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17SECTION 9 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18SECTION 10 PARTS LIST INCLUDING CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21WARRANTY
SECTION 1 SAFETY PRECAUTIONS FOR GMAWWELDING GUNS READ BEFORE USINGSR7 (MIG) 2015-09Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.1-1. Symbol UsageDANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or explained in the text.NOTICE Indicates statements not related to personal injury. Indicates special instructions.This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid thehazards.1-2. Arc Welding HazardsThe symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the welding power source Owner’s Manual. Readand follow all Safety Standards.BUILDUP OF GAS can injure or kill.D Shut off compressed gas supply when not inuse.D Always ventilate confined spaces or use approved air-supplied respirator.Only qualified persons should install, operate, maintain, andrepair this unit.During operation, keep everybody, especially children, away.ELECTRIC SHOCK can kill.D Always wear dry insulating gloves.D Insulate yourself from work and ground.D Do not touch live electrode or electrical parts.D Replace worn, damaged, or cracked guns or cables.D Turn off welding power source before changing contact tip or gunparts.D Keep all covers and handle securely in place.FUMES AND GASES can be hazardous.D Keep your head out of the fumes.D Ventilate area, or use breathing device. Therecommended way to determine adequateventilation is to sample for the composition and quantity of fumesand gases to which personnel are exposed.D Read and understand the Safety Data Sheets (SDSs) and themanufacturer’s instructions for adhesives, coatings, cleaners,consumables, coolants, degreasers, fluxes, and metals.WELDING can cause fire or explosion.D Do not weld near flammable material.D Do not weld on containers that have held combustibles, or on closed containers such astanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).D Watch for fire; keep extinguisher nearby.D Read and understand the Safety Data Sheets (SDSs) and themanufacturer’s instructions for adhesives, coatings, cleaners,consumables, coolants, degreasers, fluxes, and metals.MOVING PARTS can injure.D Keep away from moving parts.D Keep away from pinch points such as driverolls.ARC RAYS can burn eyes and skin.Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.D Wear an approved welding helmet fitted with a proper shade of filterlenses to protect your face and eyes from arc rays and sparkswhen welding or watching (see ANSI Z49.1 and Z87.1 listed inSafety Standards).D Wear approved safety glasses with side shields under yourhelmet.D Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.D Wear body protection made from durable, flame-resistant material(leather, heavy cotton, wool). Body protection includes oil-freeclothing such as leather gloves, heavy shirt, cuffless trousers, highshoes, and a cap.HOT PARTS can burn.D Allow gun to cool before touching.D Do not touch hot metal.D Protect hot metal from contact by others.OM-1213 Page 1
NOISE can damage hearing.Noise from some processes or equipment candamage hearing.D Check for noise level limits exceeding thosespecified by OSHA.D Use approved ear plugs or ear muffs if noise level is high.D Warn others nearby about noise hazard.WELDING WIRE can injure.READ INSTRUCTIONS.D Read and follow all labels and the Owner’sManual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.D Use only genuine replacement parts from the manufacturer.D Perform installation, maintenance, and service according to theOwner’s Manuals, industry standards, and national, state, andlocal codes.D Keep hands and body away from gun tip whentrigger is pressed.1-3. Proposition 65 WarningsWelding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)This product contains chemicals, including lead, known tothe state of California to cause cancer, birth defects, or otherreproductive harm. Wash hands after use.1-4. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,is available as a free download from the American Welding Society athttp://www.aws.org or purchased from Global Engineering Documents(phone: 1-877-413-5184, website: www.global.ihs.com).Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).Safe Practices for Welding and Cutting Containers that have Held Combustibles, Ameri
And 30A. 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. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Thank you and .
