OM-316 087 083Q August 2004 Processes Stick (SMAW) Welding Description AC/DC, 300/200 AC/DC Models: 225 And 300 Models: Arc Welding Power Source Thunderbolt XL R AC/DC, 300/200 AC/DC, 225, And 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 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 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. MOVING PARTS can cause injury. 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. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie « NOTA » ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance.
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées. Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. D Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLOSION LES ORGANES MOBILES peuvent causer des blessures. D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle. D Se tenir à l’écart des organes mobiles comme les ventilateurs. D Maintenir fermés et bien fixés les portes, panneaux, recouvrements et dispositifs de protection. D Ne pas installer l’appareil à proximité de produits inflammables.
2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.
SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperes Single Phase Do Not Switch Under Load On Off Output Alternating Current Electrode Positive Electrode Negative Direct Current Volts Work Electrode V Welding Arc Input Hz Hertz 3-2. Manufacturer’s Rating Labels Rating Label For EN/FR Machines Rating Label For All Other Machines INPUT SERIALNO. STOCK NO.
SECTION 4 − INSTALLATION 4-1.
4-2. Duty Cycle Charts A. For AC/DC Models Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Y 20% Duty Cycle at 225 Amperes. Exceeding duty cycle can damage unit and void warranty. 2 Minutes Welding 8 Minutes Resting A. For 115/230, 230, And 460 Volt Models (225/150 Amperes*) B. For 220, 230/400, And 460 Volt Models (300/200 Amperes) *These models have a 15% duty cycle when used with 50 Hz input power. 086 727 / 099 602-A B.
4-3. Volt-Ampere Curves A. For AC/DC Models The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall between the curves shown. A. For 115/230, 230 And 460 Volt Models (225/150 Amperes) 90 80 80 70 70 60 50 DC Volts AC Volts 60 40 30 50 40 30 20 20 10 10 0 0 0 50 100 150 200 250 300 350 0 50 100 AC Amperes 150 200 250 DC Amperes B.
B. For AC Models The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall between the curves shown. A. For 115/230 And 230 Volt Models (225 Amperes) 90 A=LOW RANGE 80 B=HIGH RANGE 70 AC Volts 60 50 40 30 20 A 10 A B B 0 0 50 100 150 200 250 300 AC Amperes C. For 230/400 Volt Model (300 Amperes) B.
4-4. Selecting A Location 1 1 18 in (457 mm) for airflow V A KW LR5071 Rating Label (See Section 3-2) Locate unit near correct input power. Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.
4-5. Installing Electrode Holder And Work Clamp Y Turn Off unit and disconnect input power before installing electrode holder or work clamp. Removing Barrel From Electrode Holder 1 2 3 4 3 Loosen set screw through access hole and slide barrel away from electrode holder.
4-7. Electrical Service Guide Input Voltage 115 220 230 400 460 Input Amperes At Rated Output 95 [70] 47.5 [67] [39] 23.
4-8. Internal Connections For Operating 115/230 Volts, 225 Amperes AC And AC/DC Models From 115 Volts NOTE Follow applicable electrical codes and have a competent electrician make internal connections. Note the input amperes as stated in Section 4-7. 1 Power Switch S1 Terminals 230V Connection 6 To Fan To Fan 2 4 1 3 115V Connection 2 6 To Fan To Fan 3 7 2 3 11 2 4 8 8 5 10 5 4 Tools Needed: 5/16, 3/8 in 9 (cut tie wraps) 7/16 in Ref.
4-9. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300 Amperes AC Models From 230 Volts NOTE Follow applicable electrical codes and have a competent electrician make internal connections. Note the input amperes as stated in Section 4-7. Y Turn Off unit and disconnect input power. 4 1 2 3 4 Primary Coil Lead 4 Lead 4 Insulation Sleeving Power Switch Lead 4 Lead Connection Hardware Slide Sleeving down, and disconnect one lead 4 from the other. Remove sleeving.
4-10. Connecting Input Power 1 For Models Supplied With Plug Y Disconnect and lockout/tagout input power before installing receptacle. Y Have only qualified persons make this installation. See rating label in Section 4-4, and be sure to supply correct input power. 1 3 Proper Receptacle (User-Supplied) Receptacle must comply with applicable codes. 2 Input And Grounding Conductors See size and length using Section 4-7. Conductors must comply with applicable codes.
SECTION 5 − OPERATION 5-1. Controls A. Controls For AC/DC Models 1 2 3 Amperage Adjustment Control Power Switch Mode Switch For DC Weld Output Use mode switch to select polarity of dc output, Electrode Positive/DCEP (+),or Electrode Negative/DCEN (−). For AC Weld Output Use mode switch to select ac low range or high range output. 3 2 1 Ref.
B. Controls For AC Models 1 2 3 Amperage Adjustment Control Power Switch Mode Switch Use mode switch to select ac low range or high range output. 3 2 1 Ref.
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Cables Replace Unreadable Labels 6 Months 12 Months Blow Out Or Vacuum Inside, During Heavy Service, Clean Monthly OR Lubricate Shunt Block (See Section 6-2) 6-2. Lubricating Shunt Block And Anti-Noise Adjustment Y Turn Off welding power source and disconnect input power. 1 Wrapper Remove wrapper. 2 Shunt Block .
6-3. Reinstalling Amperage Adjustment Indicator Y Turn Off welding power source and disconnect input power. 1 1 Wrapper Remove wrapper from unit. 2 3 4 6 Insert crank handle onto shunt shaft protruding through front panel and turn crank handle to adjust shunt to the proper vale of “X”, depending on model (see detail of transformer and shunt. 5 2 3 7 Crank Handle Shunt Shaft Transformer And Shunt (Located Inside Unit) Remove crank handle.
6-4. Troubleshooting Trouble No weld output; fan does not run. Remedy Be sure line disconnect switch is in On position (see Section 4-10). Check and replace line fuses if open. Reset breakers if necessary (see Section 4-10). Fan does not run; weld output okay. Be sure nothing is blocking movement of fan. If fan does not run freely, replace fan motor. Erratic weld current. Clean and tighten all weld cable connections. Erratic arc with excessive spatter. Use dry, properly stored electrodes.
SECTION 7 − ELECTRICAL DIAGRAMS 191 364 Figure 7-1. Circuit Diagram For AC/DC (230 Volts) Models 191 365 Figure 7-2.
NEUTRAL (WHT) S1 CONNECTED FOR 115 VOLTS CONNECTED FOR 230 VOLTS LINE (BLK) S1 GRN GRN FM 1 PRI 2 PLG1 3 S1 4 FM 1 PRI 2 PLG1 T1 3 4 T1 SR1 SEC R Z1 S2 WORK ELECTRODE Figure 7-3. Circuit Diagram For AC/DC (115/230 Volts) Models 191 363-A S1 220 VOLT ONLY FM GRN PRI SR1 T1 POWER CORD SEC S.O.P. S.O.P. R Z1 S2 WORK ELECTRODE 191 368 Figure 7-4.
S1 CONNECTED FOR 400 VOLTS CONNECTED FOR 230 VOLTS 230V GRN FM POWER CORD 1 PRI 2 3 FM 1 PRI 2 3 4 4 T1 T1 SR1 SEC R Z1 S2 WORK ELECTRODE Figure 7-5. Circuit Diagram For 300/200 AC/DC (230/400 Volts) Models 191 369 S1 460 VOLT ONLY 230V FM GRN PRI POWER CORD SR1 T1 SEC S.O.P. S.O.P. R Z1 S2 WORK ELECTRODE 191 370 Figure 7-6.
S1 230 VOLT ONLY FM GRN PRI T1 PLG1 SEC AC HIGH S2 AC LOW WORK ELECTRODE 191 362 Figure 7-7. Circuit Diagram For 225 (230 Volts) Models S1 CONNECTED FOR 230 VOLTS NEUTRAL CONNECTED FOR 115 VOLTS (WHT) LINE (BLK) S1 S1 GRN GRN FM PLG1 1 PRI2 3 FM PLG1 1 PRI2 4 3 4 T1 T1 SEC S2 WORK ELECTRODE Figure 7-8.
S1 220 VOLT ONLY FM GRN PRI T1 POWER CORD S.O.P. SEC AC HIGH S2 AC LOW WORK ELECTRODE 191 366 Figure 7-9. Circuit Diagram For 300 (220 Volts) Models S1 CONNECTED FOR 400 VOLTS CONNECTED FOR 230 VOLTS 230V GRN FM POWER CORD 1 FM PRI 2 3 4 1 PRI 2 3 4 T1 T1 SEC S2 WORK ELECTRODE 191 367 Figure 7-10.
SECTION 8 − WELDING METHODS & TROUBLESHOOTING mod5.1* 9/92 A. Welding Methods 8-1. Shielded Metal Arc Welding (SMAW) Procedure 5 4 2 3 6 1 7 Tools Needed: 151 593 1 5 Electrode Holder Position Make sure workpiece is clean before welding. Workpiece 6 Arc Length 2 Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. Work Clamp Place as close to the weld as possible.
308L 450 400 350 300 AMPERAGE RANGE 200 150 100 50 250 USAGE Ni-Cl PENETRATION 7024 POSITION 7018 AC 7014 DC* 6013 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 ELECTRODE 6010 & 6011 DIAMETER ELECTRODE 8-2. Electrode And Amperage Selection Chart 6010 EP ALL 6011 EP ALL DEEP MIN.
8-3. Striking An Arc Scratch Start Technique 1 2 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it. 3 Tap Start Technique 1 2 Bring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high.
8-5. Weld Bead Characteristics Poor Weld Bead 1 2 4 3 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 S-0053-A Good Weld Bead 1 5 2 4 3 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1/8 in (3.2 mm) thickness in metals being welded. 4 No Overlap 5 Good Penetration Into Base Metal Ref. S-0052-B 8-6.
8-7. Electrode Movement During Welding 1 2 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side To Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode. .A single stringer bead is satisfactory for most narrow groove weld joints. For wide groove weld joints or bridging across gaps, a weave bead works better. 3 S-0054-A 8-8. Butt Joints 1 2 2 1/16 in (1.
8-9. Lap Joints 30° Or Less 30° Or Less 1 Electrode 2 Single-Layer Fillet Weld Move electrode in circular motion. 3 1 2 Multi-Layer Fillet Weld Weld a second layer when a larger fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength. 1 3 Single-Layer Fillet Weld Multi-Layer Fillet Weld S-0063 / S-0064 8-10. Tee Joints 1 1 2 1 2 Electrode Fillet Weld Keep arc short and move at definite rate of speed.
Table 6-2. Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high Reduce arc length or voltage. Table 6-3. Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input.
Table 6-5. Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Good Penetration Possible Causes Excessive heat input. Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. Table 6-6. Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Excessive heat input.
SECTION 9 − PARTS LIST . Hardware is common and 31 not available unless listed. 802 245-E Figure 9-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Main Assembly .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1 ........... 1 ........... 2 ........... 3 . . . . S2 . . . 3 . . . . S2 . . . 4 ........... 5 ........... 6 ........... 7 . . . . T1 . . . 7 . . . . T1 . . . 7 . . . . T1 . . . 7 . . . . T1 . . . 7 . . . . T1 . . . 7 . . . . T1 . . . 7 . . . . T1 . . . 8 ...........
Notes
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
Notes TM-188 304 Page 2 Invision 354MP
Effective January 1, 2004 (Equipment with a serial number preface of “LE” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number.
