OWNER`S MANUAL - Public Surplus
Contents
1. 1 side de de TE 039 049 TERMINAL BOARD red 2 13 R3 083784 RESISTOR WW fxd 100W 10 ohm 1 qUMES eo mat 605 742 CLIP mtg resistor 500 ID core 1 AE N ot 128 580 ENCLOSURE HF panel 1 16 C3 106935 CAPACITOR polyp film 10uf 250VAC 1 17 T2 074398 TRANSFORMER high voltage 115V pri 3600V sec 30mA 1 TEL 107 219 STRIP insulator usse DRE eee X RE ER Hebr 1 ME EA oid iv 020 623 SPARK GAP ASSEMBLY consisting of i EE EE EO 095 621 BASE spark gap 1 DB exerce 020 622 xa HOLDER points dp hanga eee GEE ir mn ent E eee aS 4 pr RE G 020603 POINT spark gap 4 EE ee es 602 023 SCREW cap stl sch 10 24 x 750 4 23 C13 096761 CAPACITOR mica 002uf 10000VDC 1 eee ss N OES 097 922 KNOB pointer o 21G 0p EE 2 Kna hs no EER ge N able d TERES ATE 1 25 GS1 4109930 VALVE 24VAC 2 way 1 4 IPS 1 8 orf 1 Na clon Sa 010 296 FITTING hose brs elb M 1 4NPT x 625 18RH 2 Recommended Spare Parts These items are not part of HF Panel BE2. 1 GEET S3 089085 SWITCH tgi SPST 20A 125VAC 1 Tau 82 011622 SWITCH tal 3PDT 15A 125VAC 1 8 uu Si 011609 SWITCH tgl SPOT 15A 125VAC 1 9 CB1 083432 CIRCUIT BREAKER man reset 1P 10A 250V 1 10 ceres 057 359 BLANK snap in nyi 375mtg hole 1 11 CB2 093995 CIRCUIT BREAKER man reset 1P 15A 250VAC 1 Ierd 010357 NUT speed No 2clipon 2 13 CAE an 196 664 5 CAPACITOR SE SERE IEerkeene nep d e WRIST Derbi aq Ee 1 14 RC2 604 176 RECEPTACLE str dx grd 2P3W 15A 125V 1 ag At RA IN NAG 073 690 PLUG str grd armd 2P3W 15A 125V Arrow Hart 5965V 15 PLG51 084198 CONNECTOR rect 6skt plug Amp 87159 6 included w SR1 1 EE Fuga 081 378 CONNECTOR rect skt 22 18ga Amp 102100 2 6 16 PLG50 141642 CONNECTOR PLUG A SOCKETS consisting of 1 MET ee nes aang 113746 CONNECTOR rect skt 24 18ga Molex 39 00 0038 16 17 PC2 157848 CIRCUIT CARD relay 1 ya EE 083 147 GROMMET scr 8 10 panel hole 312sq 500 high 8 E ards here 098 991 ENCLOSURE circuit card 1 20 FL1 084171
3. ST 158 639 A Figure 3 3 Overall Dimensions And Base Mounting Hole Layout 3 3 Selecting And Preparing Weld Output Cables Tools Needed Welding Amperes 2 N ad 100 ft 30 m Or Less 10 To 60 Duty Cycle sa D T 10 ft 3 m FT For Example Total Cable Length In Weld Circuit 20 ft 6 m 1 Weld Output Cable Determine total cable length in weld circuit and maximum welding amperes Use Table 3 1 to select proper cable size Use shortest cables possible Do not use damaged cables 2 Terminal Lug Use lugs of proper amperage ca pacity and hoie size for connecting to work clamp or electrode holder and weld output terminals 3 Insulated Etectrode Holder 4 GTAW Torch Instail according to manufacturer s instructions 5 Work Clamp Install onto work cable sb6 5 11 92 S 0752 Figure 3 4 Selecting And Preparing Weld Output Cables Table 3 1 Weld Cable Size 150 ft 45 m 60 Thru 100 Duty Cycle Total Cable Copper Length In Weld Circuit Not Exceeding 200 ft 250 ft 300 ft 400 ft 60 m 70 m 90 m 120 m 10 Thru 100 Duty Cycle Weld cable size AWG is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere OM 351 Page 4 S 0007 C 3 4 Lower Front Panel 1 Access Door Loosen screw and open access door 2 Bar Route all cables and hoses und
4. March 1993 Form OM 351H er Effective With Serial No KD368924 OWNER S MANUAL 330ST Aircrafter CC AC DC Welding Power Source For SMAW And GTAW Welding 300 Amperes 32 Volts AC DC At 6096 Duty Cycle Single Phase Input Power Protection For Control Circuitry 24 And 115 VAC And Overheating 14 Pin Remote Receptacle High Frequency Switch W Read and follow these instructions and all safety blocks carefully W Give this manual to the operator w Have only trained and qualified persons in stall operate or service this unit W For help call your distributor w or MILLER ELECTRIC Mfg Co P O Box 1079 Appleton WI 54912 414 734 9821 cover 8 92 ST 110 867 F PRINTED IN USA W Call your distributor if you do not understand the directions MILLER S TRUE BLUE LIMITED WARRANTY Effective January 1 1992 Equipment with a serial number preface of KC or newer This limited warranty supersedes ali previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below MILLER Fiectric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new MILLER equipment sold after the effective date of this limited warranty is free of de fects in material and workmanship at the time it is shipped by MILLER THIS WAR RANTY IS EXPRESSLY IN LIEU OF
5. gt CRI Have Factory Authorized Service Station check Relay Control i board PC2 Wandering arc poor control of direc Reduce gas flow rate tion of arc Select proper size tungsten Properly prepare tungsten OM 351 Page 22 SECTION 6 ELECTRICAL DIAGRAMS a2anos Jamog BuipjoA 104 weibeig 12412 L 9 94n614 466 SEL OS Tat 140 nons 3411 3Hil100S EN 1509 10d5 ae Gi Es 7 l l FI 1 ill e Ne Pd zo t014 e zs SEH L ACACACATACA A A A AT e gt Kan 9 0 a va of 4 oa 98 3e mta a t zc d ae aoe eo si er Nora 5 E 2594 2594 NO Hg YG 4 as gt 1991471824 NO av wy 3 IYO CONINOO AY TRY df un r 0591 0594 NO H Y bi 18 a 234 I zou ze ish EF EP co ELE 7 H f Ed T S a Z ung vv P gt KAL sai 77 78 39vifacev lt ni S 20v Qv 3v D y y y y_ _ ed Dad MOS sd fe A HK Lo z zz LE avis rad IH E 8 NI HI UJ S E T a Cie Lat JA 20 a SBILIN DI 1 2v ELSE d o e EN H 300413313 c en z 9 1e e Sg ei 7 c o 08 MT 23 e NG HOTH ze YA e 1 D R ZE x c 330 AE gt gt aard T J oF ss o a KOI va za 6 CF Ap EL EL IL OL 47 DY 00000000001 HT H 9 3 3 0 2 8 v 99900009 Iv 300812313 29 12 29 7 ee lo EE KH E7 2v UIYHOT140 X v 1928 GE E Coen 1993d 1924 Mel
6. gt put Be sure Range Selector switch is not between positions Check remote control Erratic weld output gt Clean and tighten all weld connections Be sure electrode is dry and proper type for SMAW Be sure tungsten is correct size for GTAW Use proper size and type weld cable OM 351 Page 21 Trouble Section Fan motor FM does not run Check Power switch S1 Check fan motor FM No 115 volts ac output at duplex recep Reset circuit breaker CB2 tacle RC2 weld output available Tungsten electrode oxidizing and notre Shield weld zone from drafts AN maining bright after conclusion of weld Increase postflow time Check and tighten all gas fittings Properly prepare tungsten Replace torch parts if water has leaked into torch Lack of high frequency difficulty in es Select proper size tungsten tablishing an arc Place High Frequency switch in correct position pl Figure 4 11 Check High Frequency Intensity control R7 setting Figure 4 11 Be sure that electrode holder cable is not close to any grounded gt metal Check cables and torch for cracked insulation or bad connections Ed Repair or replace necessary parts Check spark gaps and adjust if necessary No high freguency Check position of High Frequency switch S4 If High Frequency switch S4 is in Start position check control relay
7. PIN spring CS 156 x 625 e Er 094 609 COUPLING shaft extension VELDE LS IL 121463 SHAFT extension D EE 106 398 PIN spring CS 156 x 625 122 sies 107 881 BRACKET support transformer rear 13 C20 21 091141 CAPACITOR 0 ane 14 TE 084 587 TERMINAL ASSEMBLY pri Fig 9 4 EE de 098 301 FRAME upright EE unk nee AUS 134 771 PLUG protective 640sq pababa ing D4 5 082456 DIODE ASSEMBLY 16 W ox 137902 CONTACTOR eer NEEN Res BERE NEL NAYANG lisser 026 627 GASKET lifting eye 18 S5 184630 SWITCH range mc 030 170 BUSHING snap in nyl 750 ID x 1 000mtg hole 20 S6 134629 SWITCH polarity range 21 C1 107 211 CAPACITOR polyp met film 35uf 480VAC mentees M sine BEE 025 142 BRACKET mtg capacitor KOR sos E giis Fig 9 5 PANEL rear wicomponents 24 R5 030965 RESISTOR WW fxd 100W 100 ohm 25 cus Z 098 302 STABILIZER consisting of URE TP1 026 181 THERMOSTAT
8. FILTER line pwr 115 250V 1 21 1T 098 828 BLOCK term 10A 10P 1 22 ox ur exe 092 344 HEAT SINK elec Ute cies o ate gie es 1 23 Shunt 044968 SHUNT resistor 1 24 016 17 sa 109689 CAPACITOR e oer nng EEN DES Hei ve reb ee Ra 1 25 SR2 VR1 080907 DIODE SCR integ bridge 1 26 C14 15 111 465 2 CAPACITOR Liz dv EDEN en eH S E ETE 1 27s R8 030 908 RESISTOR WW fxd 50W 150 ohm 1 28 e R6 080601 RESISTOR WW adj 25W 1K ohm 1 x DO kn Sp IR ra 605 741 CLIP mtg resistor 312 ID core 4 30 C2 1091692 CAPACITOR ss ede Ie orare rtr mede Ron Meds atts c ana Sins 1 31 C12 031 630 CAPACITOR elctlt 22uf 50VDC 1 32 SR3 035704 RECTIFIER integ 40A 800V ee 1 atio Lf ec ET 059 712 CLIP component 437dia mig adh back 1 98 CR1 059267 RELAY end 12VDC DPDT 1 gel EG 010 494 BUSHING snap in nyl 1 375 ID x 1 750mtg hole 1 AD oos bee ee 057 357 BUSHING snap in nyl 937 ID x 1 125mtg hole 1 36 PC1 133771 CIRCUIT CARD control mag amp 1 37 PLG60 11
9. O gt OUTPUT CONTACTOR on Connect Remote Device To Use High Frequency Circuit Figure 4 11 High Frequency Controls Figure 4 12 Power Switch And Pilot Light 1 High Frequency Switch Start provides HF for arc starting only Off provides no HF Use Off for SMAW stick electrode welding Continuous provides HF continu ously throughout the weld 2 High Frequency Intensity Control Figure 3 5 Use contro to change amount of HF energy used to start and main tain the arc Set as low as practical to prevent interfering with electron ic equipment 1 Power On Push Button Switch 2 Pilot Light Power Off Push Button Switch Use push button switches to turn unit and pilot light On and Off If in put power is interrupted the power On push button must be pressed to turn the unit On again c OM 351 Page 15 The shielding gas preflow switch on the Relay Control board PC2 must be placed in the desired position when the Spot Time option is present see Section 5 4 1 Spot Time Switch Place switch in the On position to turn on spot weld circuitry Place switch in the Off position to turn off spot weld circuitry Put switch in the Off position while do ing Shielded Metal Arc Welding SMAW SPOT TIME 2 Spot Time Control oe t Use control to set time for Gas Tungsten Arc GTAW spot welds 25 Spot time begins at arc initiation If the arc is br
10. Use control to set the length oftime gas and water if applicable flows after the welding stops POSTFLOW TIME Adjust time according to size of tungsten electrode in torch OUTPUT CONTACTOR 14 on Connect Remote Device To Use Post Flow Time Control Figure 4 9 Postflow Time Control amp WARNING USING HIGH FREQUENCY WITH THE SHIELDED METAL ARC WELDING PROCESS can result in serious personal injury Place the High Frequency switch in the Off position before using the Shielded Metal Arc Welding SMAW process 1 Start Amperage Switch On provides start amperage set on Start Amperage control START AMPERAGE ad 40 HO 60 KEN Off provides no start amperage 2 Start Amperage Controi Use control to set amperage for starting arc After arc is started weld amperage siopes up or down to setting of Amperage control or remote control if one is used Start amperage is always within the range selected on the Range Selector switch Figure 4 10 Start Amperage Controls OM 351 Page 14 WARNING USING HIGH FREQUENCY WITH THE SHIELDED METAL ARC WELDING PROCESS can result in serious personal injury Place the High Frequency switch in the Off position before using the Shielded Metal Arc Welding SMAW Process HIGH FREQUENCY 40 50 80 2 HF 1 30 Lig 20 80 HER HF START O CONT 10 90 HF O 0 100 OFF HIGH FREQUENCY INTENSITY
11. install amp Select Put On Insert Turn On Connect Electrode Personal Safety Set Controls Electrode Welding Power Equipment Equipment Into Holder Source Begin Welding Figure 4 17 Sequence Of Shielded Metal Arc Welding SMAW ssb7 1 9 92 OM 351 Page 17 SECTION 5 MAINTENANCE amp TROUBLESHOOTING amp WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts MOVING PARTS can cause injury Keep away from moving parts Turn Off welding power source and disconnect input power before inspecting maintaining or servicing e STATIC ELECTRICITY can damage parts on circuit boards Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proot bags and boxes AA Maintenance to be performed oniy by qualified persons swarn8 1 10 91 HOT PARTS can cause severe burns Allow cooling period before maintaining or servicing 5 1 Routine Maintenance Turn Off ail power before maintaining mr 3 Months f V Replace ts Cracked Parts Cables 14 Pin Cord Tighten Weld Terminals Gas Hose Torch Cable Replace d 6 Months Unreadable Blow Out Or Vacuum Adjust Spark Gaps ST 149 841 A Figure 5 1 Maintenance Scheduie 5 2 Overload Protection amp WARNING 7 READ SAFETY BLOCKS at start of Section 5 before proceeding A Overheating Thermo
12. t Cap 2 Cylinder Valve OUTPUT CONTACTOR Remove cap stand to side of valve and open valve slightly Gas flow blows dust and dirt from vaive Close valve 3 Cylinder 4 Regulator Flowmeter Install so face is vertical Remote Device 5 Gas Hose Connection Fitting has 5 8 18 right hand threads To Use Gas Valve 10 6 Flow Adjust Typical flow rate is 20 cfh cubic To Torch feet per hour Check wire man ufacturer s recommended flow rate 7 CO Adapter 8 O Ring 1 Install adapter with O ring between regulator flowmeter and CO cylin der 9 Gas In Fitting 10 Gas Out Fitting The Gas In and Gas Out fittings have 5 8 18 right hand threads Obtain proper size type and length hose and make connections as follows O IN GAS OUT D 3 Connect hose from shielding gas supply regulator flowmeter to Gas In fitting Connect shielding gas hose from torch to Gas Out fitting Close access door se ANG kanipa aj mkizi BABA 6 Argon Gas 1 5 2 Pa EE 4 5 25 Ed 3 Tools Needed 7 8 TT 1 1 8 5 8 in e e CO Gas ssb3 1 12 92 ST 158 697 A Ref ST 130 230 B Figure 3 9 Typical Regulator Flowmeter Installation OM 351 Page 7 3 9 Connecting Input Power AA WARNING HIGH FREQUENCY RADIATION can ELECTRIC SHOCK can kill interfere with radionavigation safety Do not touch live electrical parts services computers and communications equipment inp
13. a AE EO N 028 388 CLAMP thyristor rectifier 2 750 2 EE P REIN 026 947 STAND OFF insul 250 20 x 1 000 Ig x 312thd 2 PM T TNCS 028 516 PIN spring CS 125 x 250 4 ST 110 840 A Figure 9 5 Panel Rear w Components BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 351 Page 35 Figure 9 6 HF Panel OM 351 Page 36 Item Dia Part No Mkgs No Description Quantity 128 702 Figure 9 6 HF Panel Fig 9 1 Item 32 gate Wee ice eee ad 039 047 TERMINAL pwr output red consisting of 2 M EE ee 601 879 NUT stl hex full 500 13 1 E ELE s 039 044 BUS BAR term bd 1 px Wut Aa 601 880 NUT stl hex jam 500 13 1 uu EE 039 049 TERMINAL BOARD red 1 ex SE 601 976 SCREW cap stl hexhd 500 13 x 1 500 1 ve 4 618 9 147869 CAPACITOR cessare ipee cue due edendo sae van eis e CR NE dase 2 DEB sco res aes 108 100 RETAINER bus bar 1 9 R7 605 828 RHEOSTAT WW 50W 1 5 ohm 1 ODIT 124 649 STRIP mig HF coil hn 1 t T3 128375 COIL HF coupling air
14. irr our ha GR KAGAD GAN WEEK ER 1 STUD pri bd brs 250 20 x 1 500 2 STUD pri bd brs 10 32 x 1 375 6 WASHER flat brs 218 ID x 460 OD x 031thk 6 LINK jumper term bd pri 2 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 351 Page 34 Item Dia Part No Mkgs No Description Quantity Figure 9 5 Panel Rear w Components Fig 9 1 Item 23 t FM 116 190 MOTOR 1 12hp 230V 1550RPM 1 ROB vin estis 087 462 BRACKET mig rectifier 2 Me DE 131361 CHAMBER plenum 14in 1 m 032 604 BLADE fan 14 in 3wg 19deg 375 bore CCW 1 MA TA 098 305 PANELE teat ae dns aie b AU n I Hiec iA 1 6 SR1 117041 RECTIFIER si diode consisting of 1 7 R9VR2 044482 SUPPRESSOR 1 8 D1 3 037956 DIODE rect 275A 300V SP 2 9 C4 7 031 689 CAPACITOR rectifier 4 10 Da 037 957 DIODE rect 275A 300V RP 1 ER SCR1 2 107 588 THYRISTOR SCR 300A 300V 2
15. riels et a les mettre a la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables Arr tez tous les mat riels apr s utilisation N utilisez pas de c bles uses endommag s mal piss s ou de calibre trop petits N enroulez pas de c bles autour de votre corps Mettez a la terre la t le souder au moyen d une bonne prise de terre Ne touchez pas l lectrode si vous tes en contact avec le circuit de soudage terre N utilisez que des mat riels en bon tat R parez ou remplacez sur le champ les pi ces endommag es Portez un harnais de s curit si vous travaillez en hauteur Fermez solidement tous les panneaux et les capots que vous observez l ex cution d une soudure Portez des lunettes de s curit approuv es Des crans lat raux sont recommand es Entourez l aire de soudage de rideaux ou de cloisons de protection contre les coups d arc ou l blouissement avertissez les observateurs de ne pas regarder l arc Portez des v tements en tissus ignifuge durable laine et cuir et des chaussures de s curit Portez un casque antibruit ou des bouchons d oreille approuv s Si le niveau de bruit est lev Ne travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et causer des blessures ou la mort Assur
16. to 500 Amps Note This may vary depending on the torch design and cable length SUGGESTED WIRE FEEDER Spray Transfer S 32S VOLTAGE SENSING WIRE FEEDERS Refer to Literature Index No M 6 21 SPOOLMATIC 30A 130 831 200 Amp 10096 duty cycle air cooled 1 Ib spool gun with 30 ft 9 1 m cable assembly WC 115A WELD CONTROL 137 546 Designed for use with the Spoolmatic 30A spool gun and a DC power source having only 115VAC available
17. 1 Sources Of Direct High Frequency Radiation ae dll Weld Zone High frequency source welder with built in HF or separate HF unit weld cables torch work clamp workpiece and work table 2 Sources of Conduction Of High Frequency Input power cable line disconnect switch and input supply wiring 3 Sources Of Reradiation Of High Frequency Ungrounded metal objects light ing wiring water pipe and fixtures external phone and power lines Figure 7 2 Sources Of High Frequency Radiation From Incorrect Installation Of High Frequency Source OM 351 Page 26 Br d di Ground All Metal Objects And All Wiring in Cutting Zone Using 12 AWG Wire Nonmetal Building M N 1 High Frequency Source Welder With Built In HF Or Separate HF Uni Ground metal machine case work output terminal line disconnect switch input sup ply and worktable 2 Center Point Of Welding Zone Midpoint between high frequency source and welding toreh 3 Weiding Zone A circle 50 ft 15m from center point in all di rections 4 Weld Output Cables Keep cabies short and close together Workpiece If Required Weld Zone DES Ground By Codes 5 Conduit Joint Bonding Electrically join bond all conduit sections using copper straps or braided wire ground Conduit every 50 ft 15 m 6 Water Pipe And Fixtures Ground water pipe every 50 ft 15 m 7 Exte
18. 2 Selecting A Location And Moving Welding Power Source e AA WARNING ELECTRIC SHOCK can kill e Do not touch live electrical parts e Disconnect input power conductors from deenergized supply line BEFORE moving welding power source FIRE OR EXPLOSION can resuit from placing unit on over or near combustible surfaces Do not locate unit on over or near combustible surfaces Do not install unit near flammables BLOCKED AIRFLOW causes overheating and possible damage to unit Do not block or fiiter airflow Warranty is void if any type of filter is used FUMES can be hazardous LACK OF FRESH AIR AND PROPER VENTILATION can be harmful w Do not breathe welding fumes e Place unit only where there is a good fresh air supply and proper ventilation FALLING EQUIPMENT can cause serious personal injury and equipment damage Uselifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift the unit swarni1 1 2 92 1 18 in 460 mm Open Space On Front And Rear For Good Airflow 2 Rating Label 3 Lifting Eye Use lifting eye to move unit 4 Lifting Forks If using lifting forks extend forks out opposite side of unit Locate unit near correct input pow er supply ST 158 638 Figure 3 2 Location and Movement Of Welding Power Source OM 351 Page 3
19. 6 m 122974 50 ft 15 2 m 122 975 75 ft 22 9 m WELDING TORCHES MT 18 350 AMPS MAX For hand held manual applications Only available with bonded tri flex cable assembly Explanation of Model Description MT Miller Torch 18 350 Amps 12 12 ft 3 8m cable 25 25ft 7 6 m cable V Gas Valve Note Water cooled torches require power cable adapter 116 228 MT 18 Models 116151 MT 18 12 116 152 MT 18 25 116 153 MT 18V 12 116 154 MT 18V 25 Includes torch body with handle 300HS heat shield long backcap and cable assembly MT 18 TORCH KIT 129 592 12 1 2 ft 3 8 m 129 591 25 ft 7 6 m Includes hose and hardware hook up kit THK 1 consumable accessory kit TAK 3 regulator flowmeter HRF 2425 ground cable with clamp and power cable adapter WATER COOLANT SYSTEMS For detailed information regarding coolant systems refer to Literature Index NO AY 7 2 COOLMATE 4 042 288 115 VAC 50 60 Hz 042 289 230 VAC 50 60 Hz 4 gal 15 1 L tank capacity Used with water cooled torches rated up to 600 Amps RADIATOR 1A AND 2A 042 492 Radiator 1A 115 VAC 042 493 Radiator 2A 230 VAC 1 5 gal 5 7 L tank capacity Used with water cooled torches rated up to 500 Amps WATERMATE 1A AND 2A 042 495 Watermate 1A 115 VAC 042 496 Watermate 2A 230 VAC 2 gal 7 6 L tank capacity Used with water cooled torches rated up
20. A DC Mode B AC Mode 100 t00 90 90 80 80 70 m YA E 60 p 60 jio S 50 Q 50 Q 40 amp 40 2 30 30 20 20 0 100 200 300 400 500 600 AC AMPERES 0 100 200 300 400 500 600 DC AMPERES ssb1 1 10 91 SB 108 001 A SB 107 982 A Figure 2 1 Volt Ampere Curves 2 2 Duty Cycle a CAUTION EXCEEDING DUTY CYCLE RATINGS will damage unit Do not exceed indicated duty cycles warn7 1 2 92 Duty cycle is how long the unit can operate within a ten minute period without causing overheating or damage This unit is rated at 60 duty cycle allowing welding 6 minutes out of every 10 minutes at rated load If the welding amperes decrease the duty cycle increases WELD AMPERES 30 40 50 60 mp 8 90 00 DUTY CYCLE sb1 2 2 92 SB 000 768 A Figure 2 2 Duty Cycle Chart OM 351 Page 2 SECTION 3 INSTALLATION WARNING HIGH FREQUENCY RADIATION can interfere with radionavigation safety services computers and communications equipment Have only qualified person familiar with electronic equipment perform this installation Read and follow entire Section 7 for proper location and installation requirements for high frequency equipment before installing unit 3 1 Typical Process Connections Welding With HF Off Power Source Welding Power Source With HF On Figure 3 1 Typical Process Connections 3
21. ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT NESS Within the warranty periods listed below MILLER will repair or replace any war ranted parts or components that fail due to such defects in material or workmanship MILLER must be notified in writing within thirty 30 days of such defect or failure at which time MILLER will provide instructions on the warranty claim procedures to be followed MILLER shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser and are as follows t 5 Years Parts 3 Years Labor Original main power rectifiers 3 Years Parts and Labor Transformer Rectitier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Robots 2 Years Parts and Labor LE Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer Year Parts and Labor Motor Driven Guns Process Controllers Water Coolant Systems HF Units Grids Spot Welders Load Banks SOX Transformers Running Gear Trailers Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 6 Months Batt
22. PREFLOW SPOT TIMER 042 246 Factory 042 247 Field Includes an adjustable spot time of 0 to 5 seconds and a fixed preflow time of approximately 2 seconds WATER VALVE KIT 042 038 Field only NO 20 RUNNING GEAR 041 581 Four 8 in 203 mm poly rubber blend wheels with 30 in 762 mm towing handle NO 5CR CYLINDER RACK 041 584 Used with No 20 running gear NO 3WA WELDING ACCESSORIES 040 043 35 ft 10 6 m No 1 0 electrode cable with electrode holder and lug attached 30 ft 9 m No 1 0 work cable with lugs attached welding helmet and wire scratch brush REMOTE CONTROLS AND SWITCHES RHC 14 HAND CONTROL 129 340 Miniature hand control for remote current and contactor control Dimensions 4 in 102 mm x 4 in 102 mm x 3 1 4 in 82 mm Includes 20 ft 6 m cord and 14 pin Amphenol plug RFC 14 FOOT CONTROL 129 339 Foot current and contactor control 20 ft 6 m cord and 14 pin Amphenol plug RMLS 14 SWITCH 129 337 Momentary and maintained contact rocker switch for contactor control Push forward for maintained contact and back for momentary contact Includes 20 ft 6 m cord and 14 pin Amphenol plug FTC 14 129 338 Remote fingertip control can be taped to TIG torch contactor and current control Includes 28 ft 8 5 m cord and 14 pin plug Pre wired EXTENSION CABLES FOR 14 PIN REMOTE CONTROLS 122972 10ft 3m 122973 25 ft 7
23. Page 20 5 5 Troubleshooting 44 WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts e Tum Off welding power source and disconnect input power before inspecting maintaining or servicing HOT PARTS can cause severe burns Allow cooling period before maintaining or servicing MOVING PARTS can cause injury Keep away from moving parts STATIC ELECTRICITY can damage parts on circuit boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes Troubleshooting to be performed only by qualified persons swarng 1 4 92 Table 5 1 Welding Trouble Trouble Remedy Section No weld output unit completely inop Place line disconnect switch in the On position erative pilot light PL1 not on Check and replace line fuse s or reset circuit breaker CB1 Check for proper input connections Check for proper jumper link positions Reset circuit breaker CB1 Check contactor W No weld output fan on pilot light PL1 j Ifremote control is not used place Output Contactor switch in On 3 6 position If remote control is used place switch in Remote 14 posi Figure 4 7 tion and be sure remote control is connected to Remote 14 recep Figure 4 5 tacle Unit overheated Allow unit to cool with fan On Have Factory Authorized Service Station check Relay Control board PC2 Low weld output no contro of weld out
24. SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 351 Page 37 Dia Part Mkgs No Optional Equipment Are oM 041 934 METER KIT consisting of Me NA 111 609 METER SET AC consisting of uad luy 108956 PANEL front meter box Cm 108957 ARE iuis 108 961 N2 025 645 METER volt AC 0 100 scale A2 025 649 METER amp AC 0 500 scale PO dada 025 700 FILTER HF AC amp meter Da NA 025 701 FILTER HF DC volt amp amp meter CT1 110924 TRANSFORMER current 500 5 PUES 126 752 COVER top MAT cista 010 493 BUSHING snap in nyl 625 ID x 875mtg hole Kakai HANG AUN 041 936 METER KIT consisting of Nath OE 111 610 METER SET DC consisting of EDE Se 108 956 PANEL front meter box A ote 108 957 AE OE DE 108 961 B s nn 025 638 METER volt DC 0 100 scale A is 025 664 METER amp DC 50MV 0 500 scale PA ES ds 025 701 FILTER HF DC volt amp amp meter TR TER 126 752 COVER top Shunt 030 081 SHUNT meter 50MV 500A PA kes do 010 493 BUSHING snap in nyl 625 ID x 875mtg hole MA ER 041 938 METER KIT consisting of TT 111 611 METER SET AC DC consisting of MEE 108 959 PANEL front meter box E 108 958 IDE 108 955 V2 025 645 METER volt AC 0 100 scale Mis 025 638 METER volt DC 0 100 scale AN 025 649 METER amp AC 0 500 scale MAT SEE
25. d 0998 DO FS 099390939 77 nd 1038 BF lt lt 1 094 DUYOB OHIO div 9m 13d OM 351 Page 23 o ea R6 en Hi Si El x IR E DI 3 tl E m E R 5 0 Ea x eo E 324 61T E ZI B ABC SR3 AC I3ALPLGSO U 338 PLG50 K EA lt a E bad EN puce 7 2 RCS2 2 PC 2 95C T2 115v SIA PLGE 2 AE PLGSO PLGSI ia RCSO RCS 1 OA te lee We WAZEMBE 5 2 a 0 0 lessie N 46A P1560 4 Ng pos o 38A UPLG6 8 64A R2 WIPER S6A PLGEO I Y B2A REO CHI 83A R60 CCW 18 CB2 24 RED SCR2 47 RED SCRI 25A TI PF WINOIHG 58 TE OM 351 Page 24 45B1sRZ I Figure 6 2 Wiring Diagram For Welding Power Source 3eB L ns KOHN 1 scu AOA FAH MOTOR 8 0UT END T 1OA W LOAD Na O GND BA W LINE JAW LINE eel Fe CHA pnsan Li GNO A GREEN B T OF 32C IT EJ 4F 52 48 PLG2 2 30F IT CI Guo B GREEN CBI D 18751 Sle si ji 3 LN NEN X IN 3 pa A all Sr Sa AL E alla 88 s 2 are sala Ee 3 amp dila E 8 8 ge SERE ed amp SA E Ja J BE of 22 E SE SZ 43 j PLGI a a DD DIGNO TERM 78BtS2 A d 209 A3C TI BV DLK TAP Coo zer tz i 24v euu END FT Mactri iev p nl 8 D ICITI IBV BLK BEG 31D F1 24V BLU BE
26. 26 Thorium Alloyed Tungsten Red Band Up to 25 Up to 20 Up to 15 15 40 x 15 35 5 20 25 85 20 80 20 60 50 160 10 20 50 150 60 120 135 235 15 30 130 250 100 180 250 400 25 40 225 360 160 250 400 500 40 55 300 450 200 320 3 16 500 750 55 80 400 500 290 390 1 4 750 1000 600 800 340 525 Zirconium Alloyed Tungsten Brown Band Up to 20 Up to 15 15 35 5 20 20 80 20 60 50 150 60 120 130 250 100 180 225 360 160 250 300 450 200 320 400 550 290 390 600 800 340 525 Typical argon shielding gas flow rates are 15 to 35 ch cubic feet per hour Not Recommended The figures listed are intended as a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers e 5 0009 OM 351 Page 28 8 2 Preparing Tungsten 1 1 2 Times Electrode Diameter 1 Tungsten Electrode 2 Balled End Ball end of tungsten before welding by applying either an ac amperage slightly higher than what is recom mended for a given electrode diam eter see Table 8 1 or a dc elec trode positive amperage Figure 8 1 Preparing Tungsten For AC Or DC Electrode Positive DCEP Welding 4 CAUTION Keep flammables away E 2 1 2 Times Electrode Diameter a o FLYING SPARKS AND HOT METAL can cause injury and start fires Shapetungsten electrode only on grinder with proper guards in a safe location wearing pro
27. 5093 CONNECTOR PLUG amp SOCKETS consisting of 1 ACNE 113 746 CONNECTOR rect skt 24 18ga Molex 39 00 0038 6 38 PLG61 115092 CONNECTOR PLUG amp SOCKETS consisting of 1 113746 CONNECTOR rect skt 24 18ga Molex 39 00 0038 8 39 PBT 046746 SWITCH PB Fig 9 3 1 40 PL1 048573 LIGHT ind red lens 28V 1 in EO EES N 121618 PANEL front A sonne EERDER ERE RUE gie dti N we ESI IA 1 42 bulag wana 605 583 CATCH spring loaded door 1 MK PR DE ER 134 327 LABEL warning general precautionary 1 SAM oo oet eras 121 465 DOOR access front 1 s 128 230 LABEL warning electric shock can kill etc 1 AE sese pau 109 013 BUSHING snap in ny 375 ID x 562mtg hole 2 LAG are ghee be Se eee NAMEPLATE order by model and serial number 1 L4 se NBA us 107 983 BLANK snap in nyl 500mtg hole 1 a Lens 097 924 KNOB pointer 1 AY ER EE 097 922 KNOB pointer ciis Ying ae adieu anges ete DD Dane Ee Ee 2 M pcc PLATE ident control rating order by model and serial number 1 Des ee 078 034 FASTEN
28. ATION 3 1 Typical Process Connections 3 3 2 Selecting A Location And Moving Welding Power Source 3 3 3 Selecting And Preparing Weld Output Cables 4 3 4 Lower Front Panel maradt oi Me se E er Xp er REEL ES eo Hae 5 3 5 Connecting To Weld Output Terminals 5 3 6 Remote 14 Receptacie Information And Connections 6 3 7 115 Volts AC Duplex Receptacle 6 3 8 Shielding Gas Connections 7 3 9 Connecting Input Power 8 SECTION A OPERATION 10 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenance 18 5 2 Overload Protection 18 5 3 Adjusting Spark Gaps ss SES EE EE ee ee ee ge ee ee ee ee s 19 5 4 Setting Preflow Function For Spot Weld Timer Option 20 5 5 Troubleshooting cob EER EEG ER SE DAP HUE DNA 21 SECTION 6 ELECTRICAL DIAGRAMS 23 SECTION 7 HIGH FREQUENCY 26 SECTION 8 TUNGSTEN ELECTRODE 8 1 Selecting Tungsten Ele
29. DES PERSONNES QUALIFI ES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE R PARATION D ENTRETIEN ET D ESSAI L LECTROCUTION peut tre mortelle Une d charge lectrique peut vous tuer ou vous br ler gravement L lectrode et le circuit de soudage sontsous tension au d marrage Le circuit d entr e et les circuits internes des mat riels sont aussi sous tension d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le support de roquette le logement des galets d entra nement et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre sont dangereux Ne touchez pas des pi ces sous tension Portez des gants et des v tements isolants secs et non trou s Isolez vous de la t le souder et de la mise la terre au moyen de petits tapis isolants ou autres D connectez la prise d entr e des mat riels ou arr tez leur moteur avant de les installer ou d en faire l entretien Le RAYONNEMENT DE L ARC peut br ler ies yeux et la peau le BRUIT peut endommager l ouie L arc de soudage produit une chaleur et des rayons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par certains proc d s peut endommager l ou e 1 Portez un casque de soudeur avec cran filtrant de teinte appropri e consultez la norme ANSI Z49 indiqu e ci apr s pour vous prot ger le visage etles yeux lo
30. Do not touch electrode if in contact with the work or ground Use only well maintained equipment Repair or replace damaged parts at once Wear a safety harness if working above floor level Keep ail panels and covers securely in place Wear a welding helmet fitted with a proper shade of filter see ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded Watch for fire and keep a fire extinguisher nearby Be aware that welding on a
31. ER screw sltd hd 7361g 2 When ordering a component originally displaying a precautionary label the label should also be ordered BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 351 Page 33 Item Part No No Description Quantity 046 746 Figure 9 3 Switch Push Button Fig 9 2 Item 39 1 059885 BUTTON push reset red 1 2 018606 SPRING cprsn 430 OD x 040 wire x 1 500 1 8 070068 PUSH BUTTON SET w cable 4 housing 1 4 081008 BRACKET mtg switch PB 1 5 027878 SWITCH lim leaf actg SPDT 1 Figure 9 3 Switch Push Button item Part No No 034 587 c 001 P ON 601 835 601 836 010915 083426 038888 038 887 010913 038618 5 3 1 O P S O Go lt 3 A ST 080 214 B SJ 2 lt d Lee lt Say 1 ST 087 333 B Figure 9 4 Terminal Assembly Primary Description Quantity Figure 9 4 Terminal Assembly Primary Fig 9 1 Item 14 NUT brs hex 10 32 3 ack a AD anak oles Anus Bare ner OR ya 12 NUT brs hex 250 20 jam hvy 4 WASHER flat brs 250 ID x 625 OD x 031thk 4 TERMINAL BOARD pri
32. G BIB TI LISV RED BEG het 27 NA1 28 HA1 26 HA1 23A SRI MAT 480 WOPX STUD 2SA C1 m A I3BCIT A um x all 1 BAILTEIL TAUTEI L 61 ELECT ELECTRODE 7 OUT TAP Q D X u SBALSPARK GAP SD 137 012 OM 351 Page 25 SECTION 7 HIGH FREQUENCY mod6 1 11 92 amp WARNING HIGH FREQUENCY RADIATION can interfere with radionavigation safety services computers and communications equipment f Have only qualified person familiar with electronic equipment perform this installation a HF e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop using the equipment at once e Have the installation regularly checked and maintained e Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding as shown in Figure 7 3 to minimize the possibility of interference 1 Gas Tungsten Arc Torch WA 2 High Frequency Voltage Used to help arc jump air gap be tween torch and workpiece and or stabilize the arc ae 2 3 Submerged Arc Welding Gun 4 Flux 5 High Frequency Voltage Gas Tungsten Arc Submerged Arc aag ba Dn ci NO piece Welding GTAW Welding SAW 9 9 sees Figure 7 1 Welding Processes Reguiring High Freguency
33. LOSER UNACCUMULATEUR L LECTROLYTE D UN ACCUMULATEUR peut br ler la peau et les yeux Les accumulateurs contiennent de l lectrolyte et d gagent des vapeurs explosives 1 Portez toujours un cran facial en travaillant sur La VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BR LANT SOUS PRESSION peuvent br ler la peau et ies yeux Le liquide de refroidissement d un radiateur peut tre br lant et sous pression m tal En refroidissant la soudure peut projeter du laitier Portez un cran facial ou des lunettes coques approuv es Des crans lat raux sont recommand s Portez des v tements de protection individuelle appropri s Emp chez tout contact entre une bouteille et une lectrode N utilisez que des bouteilles de gaz protecteur des d tendeurs des flexibles et des raccords concus pour chaque application sp cifique ces mat riels etles pieces connexes doivent tre en bon tat Ne mettez pas le visage devant le robinet de bouteille en l ouvrant Remettez le chapeau de bouteille apr s utilisation Lisez etrespectez les consignes relatives aux bouteilles de gaz comprim et aux mat riels connexes ainsi que fa publication P 1 de la CGA num r es dans les normes ci dessous Utilisez des machines l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez des machines dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des pris
34. NC 26 MA1 109 633 AMPLIFIER consisting of v T ida si EEN 098 194 COIL contact LH OB EE RR RR s 098 192 COIL contactac eO css rovs uw 098 193 COIL contact RH else cup 098 280 BRACKET support amplifier np 121632 BASE Er De ciate hed aa yaad tee PEERS EE N 128 702 HF CONTROL Fig 9 6 CCP DM 010 647 PIN spring CS 156 x 1 250 NE PAA EE 098 279 HANDLE switch range AE e EE E Fig 9 2 PANEL front w cmpnts 36 eth a 107 880 BRACKET support transformer front 37 T1 140 548 TRANSFORMER power main 200 230 360 consisting of AA eg EEN 140605 COIL prifsec 37 T1 140545 TRANSFORMER power main 230 460 575 consisting of EE 140 606 COIL prifsec EE da ae lathe 140505 KIT label 5 EE EE ESE BERE ERR bre e ond Replace Coils At Factory Or Authorized Service Station Quantity When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 351 Page 31 Item D
35. R 025 664 METER amp DC 50MV 0 500 scale PT 025 701 FILTER HF DC volt amp amp meter ELE 025 700 FILTER HF AC amp meter GI 110924 TRANSFORMER current 500 5 Shunt 030 081 SHUNT meter 50MV 500A AP Tare Nga 126 752 COVER top Vu enr 010 493 BUSHING snap in nyl 625 ID x 875mtg hole SE T 042 246 PRE FLOW SPOT TIMER consisting of PC2 157 844 CIRCUIT CARD relay CR1 107 524 RELAY enci 12VDC 3PDT PLG52 072566 CE 081 378 R59 028 768 097 922 KNOB pointer HOT bah ha 011 609 SWITCH tgi SPDT 15A 125VAC Description PANEL rear meter box WRAPPER meter box PANEL rear meter box WRAPPER meter box PANEL rear meter box WRAPPER meter box CONNECTOR rect 8skt plug cable Amp 87159 8 CONNECTOR rect skt 22 18ga Amp102100 2 POTENTIOMETER C sitd sft 1 T 2W 350K ohm BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 351 Page 38 Quantity OPTIONS AND ACCESSORIES ANALOG METER KITS Includes voltmeter and ammeter housed in metal case which mounts on top of power source Meters RF protected Type Factory DC 041 936 AC 041 934 AC DC 041 938 Field 041 937 041 935 041 939
36. ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Wear approved face shield or safety goggles Side shields recommended Wear proper body protection to protect skin cool they can throw off slag srt 9 92 CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high d pressure H damaged a cylinder can explode Since gas cylinders are normaily part of the welding process be sure to treat them carefully 1 Protect compressed gas cylinders from excessive heat mechanical shocks and arcs 2 Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Engines produce harmful exhaust gases ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch l
37. clean paint free location on workpiece as close to weld area as possible Sb4 1 5 92 amp WARNING ELECTRIC SHOCK can kill e Do notuse AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control Read Safety Precautions at beginning of this manual ARCING can damage switch Do not change Output Selector switch or Range Selector switch position while welding Arcing inside switch can damage contacts causing Switch to fail warn6 3 4 92 warn5 1 9 91 ELECTRODE POSITIVE ELECTRODE NEGATIVE C OR BE SURE POINTS DIRECTLY D OUTPUT 1 Output Selector Switch Use switch to select weld output Figure 4 4 Output Selector Switch OM 351 Page 11 Amperage ranges on the unit nameplate are for GTAW welding See Table 2 1 for SMAW ranges 1 Range Selector Switch 20 2807 AC 20 280 DC Use switch to select ac or dc weld amperage range If desired amperage is in the over lapping area of two ranges set switch in the lower range for better fine amperage control see Figure 4 8 OR POINTS D OUTPUT DIRECTLY Figure 4 5 Range Selector Switch 1 Amperage Adjustment Con trol Use control to adjust amperage within range selected by Range Selector switch The numbers are a percentage of AMPERAGE the
38. ctrical parts Wear dry hole free insulating gloves and body protection 3 insulate yourseif from work and ground using dry insulating mats or covers 4 Disconnect input power or stop engine before installing or servicing this equipment ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing NOISE 1 Use approved ear plugs or ear muffs if noise level is high FUMES AND GASES can be hazardous to your heaith Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your heaith Keep your head out of the fumes Do not breathe the fumes 2 if inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases 3 If ventilation is poor use an approved air supplied respirator 4 Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners WELDING can cause fire or explosion A Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourseif and others from flying sparks and hot me
39. ctrode 28 8 2 Preparing Tungsten 29 SECTION 9 PARTS LIST Figure 9 1 Main Assembly 30 Figure 9 2 Panel Front w Components 32 Figure 9 3 Switch Push Button 34 Figure 9 4 Terminal Assembly Primary 34 Figure 9 5 Panel Rear w Components nest 239 Fig re 9 6 HE Panel ot EE Re LAND EE ANG NG di gina e E EED eg ig La 36 Optional Equipment icu eR eek dura EER latte ped LANG Beeld wae ln 38 OM 351H 3 93 SECTION 1 SAFETY INFORMATION mod1 1 8 92 W Read all safety messages throughout this manual B Obey all safety messages to avoid injury W Learn the meaning of WARNING and CAUTION 1 Safety Alert Symbol 2 Signal Word WARNING means possible death or serious injury can happen CAUTION means possible minor MOVING PARTS can injure injury or equipment damage can Keep away from moving parts happen Do not touch live electrical parts Disconnect input power before 4 Keep all paneis and covers closed 3 Statement Of Hazard And installing or servicing when operating Result v 4 Safety Instructions To Avoid 5 Hazard 5 Hazard Symbol If Availab
40. er bar 3 Gas Out Connection Gas In Connection Work Weld Output Terminal Electrode Weld Output High Frequency Intensity Control Figure 4 11 8 High Frequency Spark Gaps Section 5 3 Close access door after making connections NO a n Tools Needed EES Ref ST 158 640 Figure 3 5 Lower Front Panel 3 5 Connecting To Weld Output Terminals WARNING a ELECTRIC SHOCK can kill e Do not touch live electrical parts Turn Off welding power source and disconnect input power before making any weld output connections swarn12 1 2 92 1 Work Weld Output Terminal For both GTAW and SMAW weld ing connect one end of work cable to Work weld output terminal and remaining end to workpiece 1 SS e 2 Electrode Weld Output Termi N nal For GTAW welding connect torch connector or cable to Electrode weid output terminal Be sure torch N connector does not touch access door when closed For SMAW welding connect elec WORK ELECTRODE trode holder cabie to Electrode e A weld output terminal e Weld output polarity is determined by position of the Output Setector switch see Figure 4 4 Close access door Tools Needed D 3 4in Figure 3 6 Weld Output Connections OM 351 Page 5 3 6 Remote 14 Receptacle Information And Connections 1 Remote 14 Receptacle RC1 2 Keyway 3 Plug 4 Threaded Collar To connect to this receptacle align keyway inse
41. eries 90 Days Parts and Labor Ed MIG Guns TIG Torches PA Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts MILLER S True Blue Limited Warranty shall not apply to 1 tems furnished by MILLER but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any Consumable components such as contact tips cutting nozzles contactors and relays Equipment that has been modified by any party other than MILLER or equip ment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER CIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the gvent of a warranty claim covered by this warranty the exclusive remedies Shall be at MILLER S option 1 repair or 2 replacement or where authorized in writing by MILLER in appropriate cases 3 the reasonable cost of repair or replace ment at an authorized MILLER service station or 4 payment of or credit for the pur chase price less reasonable depreciation based upon actual use upon return ofthe goods at customer s risk and expense MILLER S option of repair or reptacement w
42. es d air du b timent d tincelles ou d une flamme nue Sic estpossible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faitesattention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire Pouremp cher un d marrage accidentel d un syst me pendant l entretien d branchez le cable d accumulateur la borne n gative N approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur un accumulateur Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas un poste de soudage pour charger un accumulateur ou connecter provisoirement un v hicule Utilisez la polarit correcte et de l accumulateur N tez pas le bouchon de radiateur tant que ie moteur n a pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl teme
43. et le meulage produisent des clats de Les BOUTEILLES endommagees peuvent exploser Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin Les bouteilles doivent tre prot g es contre les sources de chaieur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de soudage MISE EN GARDE Les GAZ D ECHAPPEMENT DES MOTEURS PEUVENT TRE MORTELS Les moteurs produisent des gaz d chappement nocifs Li e Le CARBURANT peut causer un incendie ou 4 une explosion Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier ie niveau de carburant ou de faire le plein Ne faites pas le plein en fumant ou proche d une source Des PIECES EN MOUVEMENT peuvent causer des blessures Des pi ces en mouvement telles des ventilateurs des rotors et des courroies peuvent couper les doigts et les mains ou accrocher des v tements amples Assurez vous que les portes les panneaux les capots et les protecteurs sont bien fermes Avant d installer ou de connecter un syst me arr tez en le moteur Seules des personnes qualifi es doivent d monter des Des TINCELLES peuvent FAIRE EXP
44. ez vous que l air est propre la respiration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants Ne soudez pas de t les galvanis es ou plaqu es en plomb ou en cadmium sans les avoir gratt es fond car ces m taux et tout rev tement qui en contient peuvent alors d gager des fum es toxiques Assurez vous d une bonne ventilation et portez un respirateur adduction d air si c est n cessaire M fiez vous des incendies et gardez un extincteur a port e de la main N oubliez pas qu une soudure sur un plafond un plancher une cloison ou une paroi peut en enflammer l autre c t Ne soudez pas un r cipient ferm comme un r servoir ou un tonneau Connectez le cable de soudage le plus pres possible de la t le de soudage pour emp cher le courant de suivre un parcours long et inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne faites pas d geler des tuyaux avec un chalumeau Videz votre carquois porte lectrodes ou coupez le fil au tube contact apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon sans revers des chaussures montantes et un casque LES ETINCELLES ET LES PROJECTIONS BRULANTES peuvent causer des blessures Le piquage
45. he extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province RECEIVING HANDLING Before unpacking equipment check carton for any damage that may have occurred during shipment File any claims for loss or damage with the delivering carrier Assistance for filing or settling ctaims may be obtained from distributor and or equipment manufacturer s Transportation Department When requesting information about this equipment always provide Mode Designation and Serial or Style Number Use the following spaces to record Model Designation and Serial or Style Number of your unit The information is located on the rating label or nameplate Model Serial or Style No Date of Purchase miller 5 92 ARC WELDING SAFETY PRECAUTIONS Ak WARNING QUALIFIED PEOPLE ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live incorrectly installed or improperly grounded equipment is a hazard Do not touch live ele
46. ia Part No Mkgs No 1 R1 143976 TERRE RM edes 079 534 EM 134 734 PONG EE N 134 731 EEUU 079 739 kag We AER C8 144299 EE aa C9 144303 ERE C10 144300 EE C22 144 302 ED TC C23 144301 La sais EE 010 855 3 R60 030686 4 R12 035897 OM 351 Page 32 Description Quantity Figure 9 2 Panel Front w Components Fig 9 1 Item 35 CONNECTOR w SOCKETS consisting of 1 CONNECTOR circ skt push in 14 18ga Amp 66358 6 14 CONNECTOR circ 14 pin plug Amp 213571 2 CONNECTOR circ pin push in 14 18ga Amp 213603 1 CONNECTOR circ clamp str rlf sz 17 20 Amp 206322 2 LEAD ASSEMBLY elect 2 22 n 1 LEAD ASSEMBLY elect 1 LEAD ASSEMBLY elect 1 LEAD ASSEMBLY elect 1 LEAD ASSEMBLY elect 1 RETAINER screw No BA danse Dans RID e ah R AERE S WIS 2 POTENTIOMETER C sitd sft 1 T 2W 2 meg ohm 1 POTENTIOMETER C sltd sft 1 T 2W 1K ohm 2 36 35 34 39 Fig 9 3 40 41 ST 110 839 E Figure 9 2 Panel Front w Components Item Dia Part No Mkgs No Description Quantity Figure 9 2 Panel Front w Components Fig 9 1 Item 35 Continued D ratay S4 011610 SWITCH tgl SPDT 10A 125VAC
47. ill be F O B Factory at Appleton Wisconsin or F O B at a MILLER authorized ser vice facility as determined by MILLER Therefore no compensation or reimburse ment for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDEO HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CON TRACT TORT OR ANY CTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR RANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING IN CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY ANO ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND OISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not appiy to you This warranty provides spe cific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to t
48. ing So ciety 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Pro tection Association Batterymarch Park Quincy MA 02269 srt 9 92 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis High way Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou levard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC MISE EN GARDE LE SOUDAGE A L ARC est dangereux PROT GEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN Le soudage comme la plupart des activit s industrielles expose certains risques Le soudage n est pas dangereux lorsqu on prend des pr cautions Les consignes de s curit suivantes ne font que r sumer l information contenue dans les normes num r es ci apr s Lisez et respectez toutes ces normes SEULES
49. k allow room for fuel to expand Do not spill fuet If fuel is spilled clean up before starting engine Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 Keephands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Do not remove radiator cap when engine is hot Allow engine to cool Wear gloves and puta rag over cap area when removing cap Allow pressure to escape before completely removing cap PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Ameri can Welding Society Standard AWS F4 1 from American Weld
50. le ES mv 6 Safety Banner en READ SAFETY BLOCKS at start of WARNING En py Section 3 1 before proceeding Read safety blocks for each sym E bol shown 7 NOTE NOTE CP Turn OFF switch when using high freguency Special instructions for best oper ation not related to safety Figure 1 1 Safety Information SECTION 2 SPECIFICATIONS Table 2 1 Welding Power Source Type Of Output Direct Current Constant Current DC CC Or Alternating Current Constant Current AC CC Rated Weld Output 300 Amperes 32 Volts At 60 Duty Cycle See Section 2 2 Type Of Input Power Single Phase 200 230 460 Or 575 Volts AC 60 Hz input Amperes At Rated Output 106 At 200 V 92 A At 230 V 46 A At 460 V 36 8 A At 575 V KVA KW Used At Rated Output 21 2 kVA 16 kW Max Open Circuit Voltage 80 V AC Or DC Mode Welding Processes Gas Tungsten Arc GTAW And Shielded Metal Arc SMAW Welding Overall Dimensions See Figure 3 3 Weight Net 750 Ib 340 kg Ship 775 Ib 351 kg Options See Rear Cover Welding Ranges AC GTAW AC SMAW DC GTAW DC SMAW 5 50A 5 60 5 55 A 20 280 A 20 265 20 280 A 50 450 40 420 A 45 450 OM 351 Page 1 2 1 Volt Ampere Curves The vol ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fail be tween the curves shown o o
51. ment Screws Loosen screws Place gauge of proper thickness in spark gap Tools Needed 4 Pressure Point Apply slight pressure at point until cg 5 32 in gauge is held firmly in gap Repeat ES gauge adjustment with other gap Tighten adjustment screws 0 008 in 0 203 mm Close access door Ret ST 158 640 Ref S 0043 Figure 5 3 Adjusting Spark Gaps OM 351 Page 19 5 4 Setting Preflow Function For Spot Weld Timer Option READ SAFETY BLOCKS at start of Section 5 before proceeding To disable gas valve and prevent gas preflow for Shielded Metal Arc SMAW welding place Output Contactor switch in On position and disconnect Remote Contactor Control from Remote 14 receptacle Shielding gas preflow is available when the spot weld timer option is present Preflow provides gas flow for about two seconds before an arc is started if the spot weld timer option is pres ent set shielding gas preflow ac cording to the weld process in use Turn Off welding power source and disconnect input power Open up per front access door 1 Relay Control Board PC2 2 Preflow On Off Switch S1 Switch positions are marked on PC2 Set switch in desired position Close and secure upper front access door T owu oryx zart ACSB Tools Needed a eel Ret ST 158 641 SA 157 845 Figure 5 4 Setting Preflow Function For Spot Weld Timer Option OM 351
52. nt le bouchon PRINCIPALES NORMES DE S CURIT Safety in Welding and Cutting norme ANSI Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 d n Ith OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 0402 R men fe Pr he P W Idin ing of ThatHaveHeldH Vom AWS F4 1 American Welding Society 550 N W ET Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 sr1f 9 91 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington Va 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Asso ciation canadienne de normalisation Standards Sales 176 Rexdale Boulevard Rexdale Ontario Canada MSW 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion norme ANSI 287 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 TABLE OF CONTENTS SE CA EE N GE EE wa SECTION 1 SAFETY INFORMATION 1 SECTION 2 SPECIFICATIONS 2 1 Volt Ampere Curves 44 raa rs 2 2 2 Duty Cyce Limo ull SERE ad gue EE REF e MAGO DA Weare Glee ennt EES D 2 SECTION 3 INSTALL
53. oken during the spot time cycle the timer stops but does not reset When the spot time has ended weld output stops Postflow starts when the remote contactor is opened The spot timer resets after the contactor opens Ps OUTPUT CONTACTOR Connect Remote Device To Use Spot Time Circuit Figure 4 13 Spot Time Controls Optional 1 AC Or DC Voltmeter Voltmeter displays voltage at the 1 2 weld output terminals but not nec essarily the welding arc due to cable resistance poor connec tions etc 2 AC Or DC Ammeter Ammeter displays weld amperage output of unit Figure 4 14 Ammeter And Voitmeter Optional OM 351 Page 16 WARNING BUILDUP OF SHIELDING GAS can harm health or kill Shut off shielding gas supply when not in use warnt 1 9 91 Shielding Gas Cylinder Valve on Torch Output Control 4 4 Foot Control 3 Open valve on cylinder just before welding Torch or foot control turns weld _ OR output and gas flow on and off Close valve on cylinder when fin ished welding sb5 2 2 92 Ref S 0621 C ST 159 059 Figure 4 15 Shielding Gas Install amp Select Insert Put On Turn On Connect Tungsten See Tungsten Personal Safety Set Controis Shielding Gas Equipment Section 8 Into Torch Equipment Turn On Welding Power Begin Welding Source Figure 4 16 Sequence Of Gas Tungsten Arc Welding GTAW And Gas Tungsten Arc Spot Welding ssb8 1 9 92
54. oose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure Keep cylinders away from any welding or other electrical circuits 4 Never allow a welding electrode to touch any cylinder 5 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition 6 Turn face away from valve outlet when opening cylinder valve 7 Keep protective cap in place over valve except when cylinder is in use or connected for use 8 Read and follow instructions on compressed gas cylinders associated equipment and CGA pubiication P 1 listed in Safety Standards Use equipment outside in open well ventilated areas 2 if used in a closed area vent engine exhaust outside and away from any building air intakes Stop engine before checking or adding fuel Do not add fuei while smoking or if unit is near any sparks or open flames 3 Allow engine to cool before fueling if possible check and add fuel to cold engine before beginning job 4 Do not overfill tan
55. per face hand and body protection Wrong Tungsten Preparation Wandering Arc warn2 1 9 91 1 Tungsten Electrode 2 Tapered End Grind end of tungsten on fine grit hard abrasive wheel before weld ing Do not use wheel for other jobs or tungsten can become contami nated causing lower weld quality Ref S 0161 1 Stable Arc 2 Flat Diameter of this flat determines amperage capacity 3 Grinding Wheel 4 Straight Ground Ret S 0162 1 Arc Wander 2 Point 3 Grinding Wheel 4 Radial Ground Ref 0162 Figure 8 2 Preparing Tungsten For DC Electrode Negative DCEN Welding OM 351 Page 29 SECTION 9 PARTS LIST ST 110 838 C 32 Fig 9 6 S OM 351 Page 30 Figure 9 1 Main Assembly item Dia Part No Mkgs No Description Figure 9 1 Main Assembly eve BS AGA 098 294 PANEL side EE OES 109 035 LABEL warning electric shock can kill etc is B wena Qe 121 464 COVER 0p sen AN Kia dg eae NG Pert M A OE Naihi 110881 SCREW 312 18 x 7 000 hex hd pln stl 4 L1 098 299 CHOKE siorino Ada ET DP tex venerant 23D ERGER Ee 108 100 RETAINER bus bar D EE 012 604 HOLDER fuse crtg 30A 250V 7 F1 012610 FUSE crtg 25A 250V ee Ge Bee 121 462 SHAFT extension switch consisting 0f OB AA 106 398
56. range selected and not an ac tual value 50 Control may be adjusted while welding Ret ST 130 230 B Figure 4 6 Amperage Adjustment Control OM 351 Page 12 AA WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts e Do not touch weld output terminals when contactor is energized Do not touch electrode and work clamp at the same time Weid output terminals are tay OUTPUT itch Bwana Rowe NOR gt ETA Figure 4 7 Output Contactor Control Switch zl EXAMPLE Of Combination Remote Amperage Control swarn7 3 10 91 1 Output Contactor Control Switch Use switch to select way of control ling unit output For weld output place switch in On position For remote output control place Switch in Remote 14 position see Section 3 6 1 Amperage Control Switch Use switch to select way of control ling amperage adjustment For front pane control place switch in Panel position For remote control place switch in Remote position See Example be low 2 Remote Foot Control 3 Remote Hand Dial 4 Remote Hand Control Ree in Example Min 20 A AC Percentage Of Range 50 Max 150 AC 50 of 20 to 280 2 Min 20 AAC Tea 150 AAC Set Switches eaman Set Range ge Set Percentage Adjust Remote Control 5 159 059 Ret ST 120 923 B ST 130 230 B S 0769 S 0774 Figure 4 8 Amperage Control Switch OM 351 Page 13 1 Postflow Time Control
57. rnal Power Or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone lines 8 Metal Building Panel Bonding Meth ods Bolt or weld building panels together install copper straps or braided wire across seams and ground frame Metal Building 0695 9 Grounding Rod Consult National Electrical Code for specifi cations 10 Windows And Doorways Cover all windows and doorways with grounded copper screen of not more than 1 4 in 6 4 mm mesh 11 Overhead Door Track Ground the track Figure 7 3 Correct Installation Of High Frequency Source OM 351 Page 27 SECTION 8 TUNGSTEN ELECTRODE mod2 1 9 92 Foradditional information see your distributor for a handbook on the Gas Tungsten Arc Welding GTAW process 8 1 Selecting Tungsten Electrode Table 8 1 Tungsten Size Amperage Range Gas Type Polarity DC Argon Eiectrode DC Argon Electrode AC Argon Using AC Argon Balanced Negative Straight Polarity Positive Reverse Polarity High Frequency Wave Using High Freq Pure Tungsten Green Band 010 Up to 15 Up to 15 Up to 10 Electrode Diameter 5 20 a 5 20 10 20 15 80 10 60 20 30 70 150 10 20 50 100 30 80 125 225 15 30 100 160 60 130 225 360 25 40 150 210 100 180 360 450 40 55 200 275 160 240 450 720 55 80 250 350 190 300 720 950 325 450 250 400 2
58. rsque vous soudez ou Les VAPEURS ET LES FUM ES sont dangereuses pour fa sant Le soudage d gage des vapeurs et des fum es qu il est dangereux de respirer 1 cartez le visage pour viter de respirer les fum es 2 l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et ies vapeurs sont aspir es l arc 3 Sila ventilation est mauvaise portez un respirateur a adduction d air approuv 4 Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Le SOUDAGE peut causer un incendie RTE ou une explosion L arc produit des tincelles et des projections Avec la chaleur intense d gag e par la t le et les mat riels elles peuvent causer un incendie et des br lures Le contact accidentei de electrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie Prot gez vous ainsi que les autres contre les tincelles et les projections Ne soudez pas dans un endroit o des tincelles peuvent atteindre des mat riaux inflammables Enievez toutes les mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des tincelles et des clats br lants susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures Veillez installer ces mat
59. rt plug and tighten threaded collar Socket Information Remote Contactor A 24volts ac B Contact closure to pin A completes 24 volts ac con tactor control circuit Protected by circuit breaker CB1 Remote Amperage Voltage Control C Command reference 10 volts dc D Control circuit common E Input command signal potentiometer wiper or O to 10 volts dc The remaining sockets are not used sb7 1 8 92 Ref ST 130 230 B Ref S 0004 A S 0750 Figure 3 7 Remote 14 Connections 3 7 115 Volts AC Duplex Receptacle 1 115 Volts AC Duplex Recep tacte This welding power source sup HBV 15A WAC 1 plies up to 15 amperes of 115 volts ac power The duplex receptacle is protected from overload by circuit breaker ON CB2 see Section 5 28 Ref ST 120 923 B Figure 3 8 Connecting To 115 Volts AC Duplex Receptacle OM 351 Page 6 3 8 Shielding Gas Connections amp WARNING CYLINDERS can explode if damaged Keep cylinders away from welding and other electrical circuits Never touch cylinder with weiding electrode Always secure cylinder to running gear wall or other stationary support BUILDUP OF SHIELDING GAS can harm health or kill e Shut off shielding gas supply when not in use warn4 1 9 91 Obtain gas cylinder and chain to running gear wall or other station ary support so cylinder cannot fail and break off valve
60. stat TP1 protects the unit from damage due to overheating If stabilizer Z gets too hot TP1 opens and weld output stops The fan keeps running to cool the transformer Wait several minutes before trying to weld OM 351 Page 18 B Fuses And Circuit Breakers 1 Circuit Breaker CB1 CB1 protects transformer Ti 24 volts ac winding If CB1 opens weld output stops Manually reset CB1 2 Circuit Breaker CB2 P CB2 protects transformer T1 115 WI m Z S volts ac winding If CB2 opens devices using 115 115V 15A o AC S volts ac from duplex receptacle RC2 would stop Manually reset CB2 3 Fuse F1 See Parts List For Rating F1 protects transformer T1 control circuit winding HEI opens the unit provides mini mum output with no amperage control Turn Off welding power Source and disconnect input power before checking F1 ST 160 520 Ret ST 110 838 C Ref ST 130 230 B Ref ST 120 923 B Figure 5 2 Overload Protection 5 3 Adjusting Spark Gaps READ SAFETY BLOCKS at start of Section 5 before proceeding Turn Off welding power source and disconnect input power Loosen screw on lower front panel and open access door 1 Tungsten End Of Point Donotclean or dress tungsten Re place point if tungsten end disap pears 2 Spark Gap Normal spark gap is 0 008in 0 203 mm if spark gaps are okay reinstall door If adjustment is needed con tinue as follows 3 Adjust
61. tal 2 Donot weld where flying sparks can strike flammable material 3 Removeailflammables within 35 k 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Bealertthat welding sparks and hot materials from welding can easily go through smail cracks and openings to adjacent areas Ba FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds PROTECT YOURSELF AND OTHERS FROM POSSI AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR In welding as in most jobs exposure to certain hazards occurs Welding is safe when precautions are taken The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed on the next page Read and follow all Safety Standards HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY ARC WELDING can be hazardous BLE SERIOUS INJURY OR DEATH KEEP CHILDREN 10 11 12 13 ARC RAYS 2 Properly install and ground this equipment according to its Owner s Manual and national state and local codes When making input connections attach proper grounding conductor first 3 Turn off ali equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not wrap cables around your body Ground the workpiece to a good electrical earth ground
62. uards closed and securely in place MAGNETIC FIELDS FROM HIGH CUR RENTS can affect pacemaker operation Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding opera tions See Safety Precautions at beginning of manual for ba Sic welding safety information swamB 1 10 91 EE Eg 1 Amperage Adjustment Con troi Amperage Control Switch Spot Time Control Spot Time Switch Power On Push Button Power Off Push Button Pilot Light Output Selector Switch Circuit Breaker CB1 Section 5 2B 10 Output Contactor Control Switch 11 Range Selector Switch OON OON BOND 12 High Freguency Switch 13 115 Volts AC Duplex Recep tacle Section 3 7 14 Circuit Breaker CB2 Section 5 2B 15 Remote 14 Receptacie RC1 Section 3 6 16 Postflow Time Control 17 Start Amperage Switch 18 Start Amperage Control Ref ST 158 640 Figure 4 1 Controls Figure 4 3 Work Clamp Insulating Gloves 2 Safety Glasses With Side Shields 3 Welding Helmet Wear dry insulating gioves safety glasses with side shields and a welding helmet with a correct shade of filter see ANSI Z49 1 sb3 1 10 91 1 Work Clamp Tools Needed Use wire brush or sandpaper to clean metal at weld joint area Use chipping hammer to remove slag Gm after welding Connect work ciamp to a
63. uctor rating must comply with national state and lo cal electrical codes Use lugs of proper amperage capacity and cor rect hole size 4 Strain Relief Connector Insert conductors through strain relief 5 Input Terminai Board 6 Line Terminals 7 Ground Terminal Connect input conductors to line terminals and grounding conductor to ground terminal Install and connect input conduc tors and grounding conductor in conduit or equivalent to deener gized line disconnect switch Be sure grounding conductor goes to an earth ground Reinstall side panel 8 Line Fuses Select fuses or circuit breakers us ing Table 3 2 Install into deener Tools Needed gized line disconnect switch CFO 3 8 7 16 1 2 in ssb2 4 11 92 ST 158 637 A Figure 3 11 Input Power Connections Table 3 2 Electrical Service Requirements CU NEE EE ES ME ld DEER ow es CO WEEN fe e amang conti TEN CNN NN These values are calcuiated from the 1990 edition of the National Electrical Code NEC Circuit breaker range is 150 to not more than 200 of rated input amperage of the welding power source Article 630 12 a of NEC Standard fuse size is that closest to 150 of rated input amperage of the welding power source Article 630 12 a of NEC Input conductor size is for insulated copper wire with 75 C rating with not more than three single current carrying conductors in a cable or raceway Table 310 16 of NEC Maxim
64. um length is to prevent more than a 3 voltage drop between service entrance and input terminals of the weiding power source Articles 210 19 a and 215 2 b of NEC The grounding conductor shall be colored or identified as specified in the NEC Grounding conductor size for copper wire is not required to be larger than input conductor Article 250 95 of NEC 0092 0 OM 351 Page 9 w wm a ES o SECTION 4 OPERATION amp WARNING ELECTRIC SHOCK can kill FUMES AND GASES can be hazardous Always wear dry insulating gioves Insulate yourself from work and ground Do not touch live electrical parts Keep all panels and covers securely in place to your health Read Material Safety Data Sheets MSDSs and Keep your head out of the fumes Ventilate area or use breathing device manufacturer s instructions for material used OM 351 Page 10 WELDING can cause fire or explosion Do not weld near flammable material Watch for fire keep extinguisher nearby Do not locate unit over combustible surfaces Do not weld on closed containers Aliow work and equipment to cool before handling ARC RAYS can burn eyes and skin NOISE can damage hearing Wear welding helmet with correct shade of filter Wear correct eye ear and body protection MOVING PARTS can cause injury Keep away from moving parts Keep ail doors panels covers and g
65. ut power before inspecting or installing Have only qualified person familiar with electronic Have only qualified persons install unit equipment perform this installation A f 3 quipment para Installation must meet National Electrical Code and Read and follow entire Section 7 for proper location all other codes and installation requirements for high frequency equipment before installing unit Turn Off welding power source and disconnect A Positioning Jumper Links Jumper links allow operation on dif ferentinput voltages and are facto ry set for the highest input voltage Check input voltage available at site Remove side panel to check jump er links 1 Input Voltage Label Only One Is On Unit Look at jumper links and compare link position with unit label 2 Input Terminal Board 3 Input Voltage Jumper Links Move links to match input voltage For example use 230 volts posi tion when 230 velts input power is available Reinstall side panel or go on to Figure 3 11 230 VOLTS 460 VOLTS 1 5 010 587 B Tools Needed I RF 3 8 in CHE sin ssb5 1 2 92 Ref ST 158 637 A Figure 3 10 Input Voltage Jumper Links Location OM 351 Page 8 B Connecting Input Power Have only qualified persons make this installation Remove side panel 1 Line Disconnect Switch Of Proper Rating 2 Input Conductors 3 Grounding Conductor Select size and length using Table 3 2 Cond
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