OM-2218 186865G July 1998 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source R Maxstar 300 Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it 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 superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS The following terms are used interchangeably throughout this manual: TIG = GTAW Stick = SMAW OM-2218G SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of Conformity For European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit.) Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch 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 Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2.
ARC RAYS can burn eyes and skin. 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. 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 Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
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. FALLING UNIT can cause injury. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique – s”assurer que l’alimentation est correctement dimensionné et protégé avant de mettre l’appareil en service. LA CHUTE DE L’APPAREIL peut blesser.
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W.
SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. 1 1.1 1.2 1.3 2 1 1.1 1.2 1.3 2.1 2.2 2.3 2 2.1 2.2 2.3 3 3.1 3 3.1 3.2 3.2 3.3 3.3 4 4 4.1 + 5 + + 4.1 6 + 5 6 S-179 310 Electric shock from welding electrode or wiring can kill. Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Warning! Watch Out! There are possible hazards as shown by the symbols. 1 2 1 2 4 3 5 V V > 60 s V 3 4 5 6 S-185 836 7 6 9 8 7 8 9 1 1 2 3 ∠ = <60 ° 4 ∠ 5 Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors.
2-2.
SECTION 3 – INSTALLATION 3-1. Specifications Rated Output at 60% Duty Cycle 250 A @ 30 VDC, 60% Duty Cycle Welding Amperage Range Max. Open-Circuit Voltage Amperes Input At Rated Output, 50Hz - ThreePhase 400 V KVA KW Dimensions Net Weight 5 – 300 90 16.9 0.15* 11.7 0.10* 8.6 0.03* H: 17 in (432 mm) 82 lb (37 kg) 100 lb (45 kg) w/ auxiliary power W: 12-1/2 in (318 mm) D: 24 in (610 mm) *While idling 3-2.
3-3. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. ST-186 864 3-4. Selecting A Location 1 Lifting Handles Use handles to lift unit. 2 Movement Hand Cart Use cart or similar device to move unit. Y Do not move or operate unit where it could tip. 1 3 Rating Label Use rating label to determine input power needs.
3-5.
3-7. Remote 4 Receptacle Information A C B D 4 Socket* Socket Information A Contactor control 24 volts dc. B Contact closure to A completes 24 volts dc contactor control circuit and enables output. 24 VOLTS DC OUTPUT CONTACTOR ST-801 192-A 3-8. 115 Volts AC Duplex Receptacle, Circuit breaker (Optional), And Power Switch 3 1 1 2 115 V 7 A AC Receptacle Circuit Breaker CB1 2 CB1 protects duplex receptacle from overload. Press button to reset breaker. 3 Power On/Off Switch Ref.
3-10. Connecting Input Power Check input voltage available at site. 1 2 Input And Grounding Conductors Line Disconnect Device See Section 3-9. Y Always connect green/yellow wire to supply grounding terminal, never to a line terminal. Connect black, brown, and blue wires (L1, L2, L3) to line terminals. 2 L1 L2 L3 Green/Yellow 1 = GND/PE Y Always connect grounding conductor first. 1 Ref.
Notes OM-2218 Page 17
SECTION 4 – OPERATION 4-1. Controls (See Section 4-2) 3 2 1 12 20 4 21 5 6 22 23 7 8 24 11 10 25 9 16 17 18 TIG Function Keys 19 13 14 15 Memory Function Keys Stick Function Keys 26 Rear Panel ST-186 715-A / Ref.
4-2. Description Of Controls (See Section 4-1) . For all front panel key pad controls: press key pad to turn on light and enable function. 1 Encoder Control Use encoder control in conjunction with applicable front panel function key pads to change values for that function. 2 Ammeter Displays amperage and preset parameters for applicable pulse functions. 3 Voltmeter Displays arc voltage and preset time, in seconds, for applicable function controls. 4 4T Mode Press key pad.
4-3. Lift-Arc And HF TIG Start Procedures When Lift-Arc button light is On, start arc as follows: 1 “Touch” 2 1–2 Seconds 1 TIG Electrode 2 Workpiece Touch tungsten electrode to workpiece at weld start point, enable output with torch trigger, foot control, or hand control. Hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. An arc will form when electrode is lifted.
5-2. Blowing Out Inside Of Unit Y Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown.
5-3. Voltmeter/Ammeter Help Displays V A 1 V A HE.L P–6 V A HE.L P–7 V A HE.L P–8 7 HE.L P–0 V A 2 8 HE.L P–1 V A 3 9 HE.L P–2 V A V A HE.L P–9 V A 10 4 HE.L P–3 V A 5 11 HE.L P–4 V A HE.L P–5 HE.L P–10 6 . All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Indicates the left side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-2).
5-4. Troubleshooting Trouble No weld output; unit completely inoperative. Remedy Place line disconnect switch in On position (see Section 3-10). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-10). Check for proper input power connections (see Section 3-10). No weld output; meter display On. If using remote control, be sure correct process is enabled to provide output control at Remote 14 receptacle (see Section 3-6 as applicable).
SECTION 6 – ELECTRICAL DIAGRAM Figure 5-1.
SC-184 001-D OM-2218 Page 25
SECTION 7 – HIGH FREQUENCY 7-1. Welding Processes Requiring High Frequency 1 High-Frequency Voltage TIG – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. 1 Work TIG high_freq 12/96 – S-0693 7-2.
7-3. Correct Installation 7 Weld Zone 3 50 ft (15 m) 50 ft (15 m) 5 1 6 2 8 4 8 Ground all metal objects and all wiring in welding zone using #12 AWG wire. Nonmetal Building Ground workpiece if required by codes. 9 Metal Building 8 8 11 10 Ref. S-0695 / Ref. S-0695 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.
18 17 SECTION 8 – PARTS LIST 19 . Hardware is common and PC2 28 PC1 36 1 36 17 35 34 34 37 38 33 2 3 32 31 30 FIG.8–2–39 29 4 5 8 27–PC3 7 6 26 25 9 24 10 11 12 13 23 14 22 15 21 20 16 not available unless listed. Figure 8-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-1. Main Assembly . . . 1 . . . . . . . . . . . . . . . 126 416 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . 126 415 . . CLAMP, saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . 179 309 . . LABEL, caution falling . . . . . . . . . . . . . . . .
. Hardware is common and not available unless listed. 1 2 7 6 3 4 8 5 11 9 10 31 32 12 30 13 29 28 27 26 14 15 25 16 24 17 23 18 22 21 20 19 ST-802 006 Figure 8-2.Windtunnels w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-2. Windtunnels w/Components (Fig 6-1 Item 39) . . . 1 . . . . . HD1 . . . . . 182 918 . . . 2 . . . . . . . . . . . . . . +182 206 . . . . . . . . . . . . . . . . . . . . . 185 836 . . . 3 . . . R1,C5,6 . . . 175 194 . . . 4 . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 8-2. Windtunnels w/Components (Fig 6-1 Item 39) . . . 18 . . . . . CT1 . . . . . 175 199 . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 19 . . . . . . . . . . . . . . . 177 547 . . BUSHING, snap-in CT-mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 20 . . . . . . . . . . . . . . . 175 140 . . BRACKET, DI-DT . . . . . . . . . . . . . . . . . . . .
Notes OM-2218 Page 32
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