OM-303 155 795P September 2003 Processes Gas Tungsten Arc (TIG) Welding Shielded Metal Arc (Stick) Welding Description Arc Welding Power Source Econotig 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. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. 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. Y Marks a special safety message. . Means “Note”; not safety related. 1-2.
ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator. 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.
1-3. 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. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES.
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.
3-2.
4-2. Specifications A. 60 Hertz Models Max. Open-Circuit Voltage Rated Output KVA Dimensions TIG Welding A Range 50−165 20−50 30−160 78 200 V−60 A (3.6)* 12.0 (0.64)* H: 18 in (457 mm) Stick Welding A Range 35−165 20−50 25−130 78 460 V−33 A (1.5)* Max. Open-Circuit Voltage Rated Output KVA Dimensions 380 V−39 A (2.0)* 14.8 (0.
SECTION 5 − INSTALLATION 5-1. Selecting a Location Position unit so air can circulate. For information about sources of high-frequency see Section 9. 18 in (460 mm) 18 in (460 mm) For carts and caster kits see back of book or contact your distributor. 18 in (460 mm) ST-158 075 5-2. Typical Stick Connections Y Turn Off power before making connections. 1 2 Electrode Holder Work Clamp Connect to receptacle as shown.
5-3. Typical TIG Connections Y Turn Off power before making connections. 1 2 Connect to receptacles as shown. 6 3 4 5 7 Remote Control Torch Work Clamp Cylinder Chain or secure cylinder to running gear, wall, or other stationary support. 5 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 6 Regulator/Flow Gauge Install so face is vertical. 7 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour) (9.4 L/min). 4 1 2 3 Tools Needed: 5/8, 1-1/8 in Ref.
5-4. Electrical Service Guide S-0092J . For 230 V models with wall receptacle, 100% duty cycle used to calculate data below. 20% duty cycle used for all other models. Input Voltage 200 230 380 415 460 Input Amperes at Rated Output 59 52 39 36 33 Standard Fuse or Circuit Breaker Rating (Max. Recommended) 90 Amps 80 Amps 60 Amps 50 Amps 40 Amps Input Conductor Size (Min.
SECTION 6 − OPERATION 6-1. Controls 6 1 2 3 8 5 7 4 Ref. ST-155 790-F 1 Weld Process Switch Use switch to select weld process. In Stick position (down), weld output goes On and Off with Power switch. In GTAW (TIG) position (up), remote control device turns on and adjusts weld output of unit as limited by Amperage control. Built-in arc starter comes on when needed to start or stabilize welding arc. No adjustments needed for arc starter.
6-2. Example of Front Panel Amperage Control Select weld process. Select range and polarity. In Example: Range = DC Percentage of Range = 50% Weld Amperage = 33 A DC Select percentage. 6-3. Example of Remote Amperage Control Select weld process. Select range and polarity. Select percentage. GTAW Welding Amperage Range or Connect remote control.
6-4. Process and Material Thickness Guide Label Guideline For Welding Process And Output For Material Material Thickness Material And Weld Output 22 ga 20 ga 0.033 in 0.036 in 0.8 mm 0.9 mm 18 ga 0.048 in 1.2 mm 16 ga 0.06 in 1.5 mm 14 ga 0.07 in 1.8 mm 12 ga 0.1 in 2.5 mm 11 ga 0.125 in 3.2 mm 10 ga 0.14 in 3.6 mm Steel Or Stainless Steel ( ) DCEN ELECTRODE NEGATIVE 6 ga 0.186 in 4.8 mm 2 ga 0.25 in 6.3 mm − 0.25+ in 6.
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Repair or replace cracked gas hose. Replace o-ring in Electrode/Gas Output receptacle if cracked. 6 Months Blow out or vacuum inside. Or 7-2. Troubleshooting Trouble No weld output; fan does not run.
SECTION 8 − ELECTRICAL DIAGRAMS SB-154 141-C Figure 8-1.
SECTION 9 − HIGH FREQUENCY 9-1. Welding Processes Requiring High Frequency 1 1 High-Frequency Voltage Helps arc jump air gap between torch and workpiece and/or stabilize the arc. Work TIG high_freq1 11/96 − S-0693 9-2.
9-3. Correct Installation Weld Zone 3 7 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. Ground workpiece if required by codes. Nonmetal Building 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.
21 23 31 36 37 38 39 47 46 48 11 1 40 32 41 43 42 34 2 3 35 45 44 34 33 30 32 29 7 28 27 4 5 26 6 25 24 7 8 9 10 22 12 11 14 15 13 19 not available unless listed. 20 16 . Hardware is common and 18 17 SECTION 10 − PARTS LIST Figure 10-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly . . . 1 . . . . . . . . . . . . . 154 335 . . BEZEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . 203 990 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 3 . . . . . . . . . . . . +165 986 . . WRAPPER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure Figure 10-1. Main Assembly (Continued) . . . 42 . . . . . PL1 . . . . . . 43 . . . . . . . . . . . . . . . . 44 . . . . . S2 . . . . . . . 45 . . . . . S4 . . . . . . . 46 . . . . . . . . . . . . . . . . 47 . . . . . . . . . . . . . . . . 48 . . . . . . . . . . . . . ................... ................... ................... ................... 157 958 155 422 154 896 089 645 177 359 010 368 026 843 198 317 192 121 176 840 134 460 . .
Effective January 1, 2003 (Equipment with a serial number preface of “LC” 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. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co.
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.
