Miller Electric wire feeder User's Manual
Contents
1. OM 877 Form 108 026 er November 1995 OWNERS MANUAL Read and follow these instructions and all m Give this manual to the operator safety blocks carefully m Have only trained and qualified persons install operate or service this unit For help call your distributor Call your distributor if you do not understand or MILLER Electric Mfg Co P O Box 1079 the directions NE Appleton WI 54912 414 734 9821 cover 1 94 ST 108 014 A 1995 MILLER Electric Mfg Co PRINTED IN USA 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 Today the people that build and sell Miller products continue the RU E Il El tradition They re just as committed to providing equipment and service 2 WARRANTY 9 4 that meets the high standards of quality and value established in 1929 Working as hard as you do This Owner s Manual is designed to help you get the most out of your every power source from Miller is backed by the most Miller products Please take time to read th2. 5 12 57 108 012 A Figure 8 3 Resistor Assembly SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 877 Page 15 Notes OM 877 Page 16 Notes OM 877 Page 17 Notes OM 877 Page 18 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 Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Miller The Power of Blue Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all 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 Electric 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 defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or rep
3. American Weld ing Society 550 N W LeJeune Rd Miami FL 33126 15 ANSI Standard Z88 2 PRACTICE FOR RESPI RATORY PROTECTION obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 SECTION 2 SAFETY PRECAUTIONS AND SIGNAL WORDS 2 1 GENERAL INFORMATION AND SAFETY A General Information presented in this manual and on various la bels tags and plates on the unit pertains to equipment design installation operation maintenance and troubleshooting which should be read understood and followed for the safe and effective use of this equipment The nameplate of this unit uses international symbols for labeling the front panel controls The symbols also appear at the appropriate section in the text B Safety The installation operation maintenance and trouble shooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others Therefore this equipment is to be in stalled operated and maintained only by qualified per sons in accordance with this manual and all applicable codes such as but not limited to those listed at the end of Section 1 Safety Rules For Operation Of Arc Weld ing Power Source OM 877 Page 6 2 2 SAFETY ALERT SYMBOL AND SIGNAL WORDS The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instruc t
4. conducted heat Hot work permit should be obtained before operation to ensure supervisor s approval that adequate precau tions have been taken After work is done check that area 15 free of sparks glowing embers and flames An empty container that held combustibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first been cleaned as described in AWS Standard A6 0 listed 7 in Standards Index This includes a thorough steam or caustic cleaning or a solvent or water washing depending on the combusti ble s solubility followed by purging and inerting with ni trogen or carbon dioxide and using protective equip OM 877 Page 2 ment as recommended in A6 0 Waterfilling just below working level may substitute for inerting A container with unknown contents should be cleaned see preceding paragraph Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut Hollow castings or containers must be vented before welding or cutting They can explode Explosive atmospheres Never weld or cut where the air may contain flammable dust gas or liquid vapors such as gasoline D Compressed Gas Equipment Standard precautions Comply with precautions in this manual and those detailed in CGA Standard P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLIN DERS listed 11 in Standards Index 1 Pressure Regulators Regulator relief valve is des
5. practices may cause seri ous injury or death When safety becomes a habit the equipment can be used with confidence These safe practices are divided into two Sections 1 General Precautions common to arc welding and cut ting and 2 Arc Welding and Cutting only Reference standards Published Standards on safety are also available for additional and more complete pro cedures than those given in this manual They are listed in the Standards Index in this manual ANSI Z49 1 is the most complete The National Electrical Code Occupational Safety and Health Administration local industrial codes and local inspection requirements also provide a basis for equip ment installation use and service 1 2 GENERAL PRECAUTIONS Different arc welding processes electrode alloys and fluxes can produce different fumes gases and radiation levels In addition to the information in this manual be sure to consult flux and electrode manufacturers Material Safety Data Sheets MSDSs for specific technical data and precaution ary measures concerning their material A Burn Prevention Wear protective clothing gauntlet gloves designed for use in welding hat and high safety toe shoes Button shirt collar and pocket flaps and wear cuffless trousers to avoid entry of sparks and slag Wear helmet with safety goggles and glasses with side shields underneath appropriate filter lenses or plates protected by clear cover glass This is a MU
6. shields for all persons who will be looking directly at the weld Others working in area See that all persons are wearing flash goggles Before starting to weld make sure that screen flaps or bay doors are closed B Toxic Fume Prevention Comply with precautions in 1 2B Generator engine exhaust must be vented to the out side air Carbon monoxide can kill C Fire and Explosion Prevention Comply with precautions in 1 2C Equipment s rated capacity Do not overload arc weld ing equipment It may overheat cables and cause a fire Loose cable connections may overheat or flash and cause a fire Never strike an arc on a cylinder or other pressure ves sel It creates a brittle area that can cause a violent rup ture or lead to such a rupture under rough handling D Compressed Gas Equipment Comply with precautions in 1 2D E Shock Prevention Exposed hot conductors or other bare metal in the weld ing circuit or in ungrounded electrically HOT equip ment can fatally shock a person whose body becomes a conductor DO NOT STAND SIT LIE LEAN ON OR TOUCH a wet surface when welding without suitable protection To protect against shock Wear dry insulating gloves and body protection Keep body and clothing dry Never work in damp area without adequate insulation against electrical shock Stay ona dry duckboard or rubber mat when dampness or sweat can not be avoided Sweat sea water or moisture be tween body and a
7. terminals inside the unit and to disconnect and isolate the other voltage load terminals Before making selection with selector switch be sure that the AMPERAGE load switches are placed in the OFF positions see Section 5 3 5 2 PILOT LIGHTS Figure 5 1 Two pilot lights are provided on the unit The pilot light for the corresponding voltage load will illuminate when input voltage is present atthe Load Bank 5 3 AMPERAGE LOAD SWITCHES Figure 5 1 CAUTION INCORRECT SWITCH POSI TIONS can damage internal components e When operating on 240 volts set amperage switches at same position or within one posi tion of another A balanced load setting at both amperage load switches is necessary to prevent resistor damage inside the unit IMPORTANT Always place both AMPERAGE load switches in the OFF position before connecting a power source when changing the 120 VOLT LOAD 240 VOLT LOAD selector switch position and after completing power source output checking procedures AMPERAGE Ref SC 096 625 Figure 5 2 Amperage Load Switch Scales Two AMPERAGE load switches provide the selection of resistance values when checking output from an ac power source The scales around each switch are cali brated in amperes with the inside scale for 120 vac input and the outside scale for 240 vac input see Figure 5 2 OM 877 Page 9 Table 5 1 Power Requirements For Load ns At Input Voltage AMPERES AT 240V 416 10 12
8. the event 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 replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES INNO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY 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 INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DI
9. 17 21 25 29 31 33 37 42 Power requirements up to 10kw at 120 or 240 vac input for various ampere load values are shown in Table 5 1 and on the unit nameplate Ampere values selected at the two AMPERAGE load switches differ between 120 and 240 VAC input as follows 120 Volt Operation When this unit is used as a 120 volt load AMPERAGE load switch settings are added together to obtain the approximate load value For example if one switch is set at 20 amperes and the other switch at 20 amperes the result would be a total load of approximately 40 amperes 240 Volt Operation When this unit is used as a 240 volt load both Amperage load switches must be set at the same value to obtain that approximate load value For example if one switch is set at 20 amperes and the other switch at 20 amperes the result would be a total load of approximately 20 amperes IMPORTANT Do not change either switch setting more than one position higher or lower from the setting on the other switch see CAUTION at beginning of Section 5 3 and on the unit nameplate 5 4 VOLTMETER Figure 5 1 CAUTION DC DIRECT SOURCES will damage unit e Do not connect unit to any dc source CURRENT The voltmeter displays the voltage of the ac power source The scale range is 0 300 in increments of 2 5 volts 5 5 HERTZ METER Figure 5 1 CAUTION DC DIRECT SOURCES will damage unit e Do not connect unit to any dc source CURRENT
10. BER WHEN ORDERING REPLACEMENT PARTS OM 877 Page 13 Dia Part Mkos No Description Quantity Figure 8 2 Panel Front w Components Fig 1 Item 2 A oies NAMEPLATE order by model and serialnumber 1 106 673 ss NONE o 1 E Re 059 734 SWITCH current 10 positon 2 a ern 106 671 BRACKET MII SWilch ei a moan a ne 2 be deeds A 106 672 PANEL baffle air 1 BERNER 036 282 TRANSFOARMER current 100 5 1 a OO aa SWITCH Selector vara ae ra ae ee dus 1 a De er 088 838 EXTENSION handle switch 1 ES 006 790 KNOB SWICK weds AAA 2 106 665 METER amp dual scale 1 a og se 099 001 LIGHT indicator red lens 250VAC 1 AA 059 778 RANDLE SMIC hier da 1 acs TS ama PEV AS 027 645 LIGHT indicator red lens 125VAC 1 ex 088 225 METER hertz 45 05 scale lucida aaa 1 oan PU 085 631 METER volt ac 0 300 1 ST 108 015 A Figure 8 2 Panel Front w Components When ordering a component originally displaying a precautionar
11. Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models 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 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 amp Spoolmate 250 Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment 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 COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In
12. NAL COMPONENTS WHEN OPERATING ON 240 VOLTS SET AMPERAGE SWITCHES AT SAME POSITION OR WITHIN ONE POSITION OF ONE ANOTHER SN 106 867 A Figure 7 1 Circuit Diagram OM 877 Page 11 SECTION 8 PARTS LIST ST 108 016 Figure 8 1 Main Assembly OM 877 Page 12 Item Par No No Description Quantity Figure 8 1 Main Assembly so 1006 66 1 gt PANEL ER Side 2 e ida 1 2 Figure 8 2 PANEL front w components 1 3 106 870 RESISTOR ASSEMBLY Figure 8 3 1 res 10682130665 PANEL KOON OD ee ok Er tenir lis 1 5 123 154 LABEL general precautionary anaana nnana nennen 1 o eee ME O edi 1 put We ua 082 139 2 PANELE FOAM OW CP ra E a 1 2 100 099 PANEL REISIGE it en cae an et nn 1 9 138 049 CASTER rbr sta 3 in bolt down nn nme 2 23410 1936168 DAS ua id Erna aa tar ne ra ne 1 ne 03 310 GASTER SWIVEL ea Ne a Aa EG Sb he Wea Nan end 2 whe 100 674 PANEL Tetalning CaDlOS errada rar Na ea 1 watt O82 1385 PANEL MOM TOWE en DS SMG A A PG ee 1 1422 090 398a PANEL TONIFCENIE 2222 energie 1 When ordering a component originally displaying a precautionary label the label should also be ordered BE SURE TO PROVIDE MODEL AND SERIAL NUM
13. SCLAIMED 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 apply to you This warranty provides specific 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 the 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 miller_warr 7 00 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Servi
14. ST for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered See 1 3A 2 Avoid oily or greasy clothing A spark may ignite them Hot metal such as electrode stubs and workpieces should never be handled without gloves Medical first aid and eye treatment First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for im mediate treatment of flash burns of the eyes and skin burns Ear plugs should be worn when working on overhead or in a confined space A hard hat should be worn when others work overhead Flammable hair preparations should not be used by per sons intending to weld or cut B Toxic Fume Prevention Severe discomfort illness or death can result from fumes vapors heat or oxygen enrichment or depletion that welding or cutting may produce Prevent them with adequate ventilation as described in ANSI Stan dard 249 1 listed in Standards Index NEVER ventilate with oxygen Lead cadmium zinc mercury and beryllium bear ing and similar materials when welded or cut may pro duce harmful concentrations of toxic fumes Adequate local exhaust ventilation must be used or each person in the area as well as the operator must wear an plied respirator For beryllium both must be used Metals coated with or containing materials that
15. The hertz meter displays the frequency of the power being supplied by the ac power source The scale range is 45 65 in increments of 0 5 Hz 5 6 DUAL SCALE AC AMMETER Figure 5 1 75 25 IN y MUA Bim 190 40 gt 50 A C AMPERES SN 107 796 Figure 5 3 Dual Scale AC Ammeter CAUTION DC DIRECT SOURCES will damage unit e Do not connect unit to any dc source CURRENT The ammeter is a dual scale meter that displays ac amperes for the 120 volts input on the top scale and ac amperes for the 240 volts input on the bottom scale SECTION 6 SEQUENCE OF OPERATION WARNING ELECTRIC SHOCK can kill e Do not touch live electrical parts Shut down auxiliary power source before connecting load bank HOT SURFACES can cause burns and melt or ignite materials e Do not touch load bank panels while oper ating Do not place any objects on load bank ARCING AND EXHAUST SPARKS can cause fire Watch for fire Have a fire extinguisher nearby and know how to use it e Disconnect welding cables from power source if applicable before testing auxiliary power output OM 877 Page 10 ENGINE EXHAUST GASES can kill e Use in open well ventilated areas or vent exhaust out of doors if applicable MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker opera tion e Wearers should consult with their doctor before going near equipment producing auxil lary power during load bank ope
16. ULES FOR OPERATION OF ARC WELDING POWER SOURCE 1 17 er En ee 1 3GeneralPrecautions aan een ee ook gk ae ae ee aw 1 Mein cule ala te ste Sa Aas en 4 1 4 Standards Booklet Index 0 0 eee nennen nennen nen 5 SECTION 2 SAFETY PRECAUTIONS AND SIGNAL WORDS 6 2 1 General Information And Safety 2 6 2 2 Safety Alert Symbol And Signal Words 6 SECTION 3 SPECIFICATIONS na 7 D SCHIDION a cada aia 7 SECTION 4 INSTALLATION di 7 Al LOCA asii a tir ae he aa as 7 4 2 Interconnecting Cord Installation 2 7 SECTION 5 OPERATOR CONTROLS 9 5 1 120 Volt Load 240 Volt Load Selector Switch 9 9 2 POLLOS Aa er ee a SU ac en ah Aa 9 53 Amperage Load SWilches cerrar ass ee a a a Sew 9 5A VOMMEI ee ii Bh ee ee ee rare ee 10 5 57 ad aa ee A ER ed 10 5 6 Dual Scale AC 10 SECTION 6 SEQUENCE OF OPERATION 10 Bris EBading Procedurenterse meets A 10 52 ONUN DOWN erteilen ee 11 SECTION 7 MAINTENANCE ccccc nen
17. acity and size 10 Place cords in storage area while unit is not in to fit 1 4 in 6 mm terminal studs Install terminals use 120V Terminal L2 Connect Black onductor Input Terminal Board Strain Relief Opening Insert NL 120V Terminal L1 Connect Front Control Panel White Conductor y Front Access Panel Removed 120V Cord Up From Cord Storage Area 240V Terminal L2 Connect Black Conductor 240V Terminal L1 Connect White Conductor Strain Relief Opening Insert 240V Cord Up From Cord Storage Area Ground Terminal Connect Ground Conductors Cord Storage Area ST 108 013 A Figure 4 1 Input Terminal Board And Ground Connectors OM 877 Page 8 SECTION 5 OPERATOR CONTROLS Hertz Meter AC Voltmeter Pilot Light For 120VAC Load NA ed No 1 20 240VAC Ya 2 Amperage Load 9 Switches I Gy Cord Storage NG Area ey x f gt Pilot Light For 240VAC Load SS A Dual Scale AC Ammeter Front Access Panel Y ST 108 014 A Figure 5 1 Front Panel Controls And Component Locations 5 1 120 VOLT LOAD 240 VOLT LOAD SELECTOR SWITCH Figure 5 1 CAUTION ARCING can damage switch con tacts e Do not change the position of the selector switch under load Arcing causes the contacts to become pitted and eventually inoperative The 120 VOLT LOAD 240 VOLT LOAD selector switch is used to select the proper voltage load
18. as tungsten arc welding GTAW and similar processes nor mally are equipped with devices that permit on off control of the welding power output When so equipped the electrode wire becomes elec trically HOT when the power source switch is ON and the welding gun switch is closed Never touch the electrode wire or any conducting ob ject in contact with the electrode circuit unless the welding power source is off b Equipment without output on off control no contactor Welding power sources used with shielded metal arc welding SMAW and similar proc esses may not be equipped with welding power output on off control devices With such equip ment the electrode is electrically HOT when the power switch is turned ON Never touch the electrode unless the welding power source 15 off 7 Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out Before installation inspection or service of equipment shut OFF all power and remove line fuses or lock or red tag switches to prevent accidental turning ON of power Disconnect all cables from welding power source and pull all 115 volts line cord plugs Do not open power circuit or change polarity while weld ing If in an emergency it must be disconnected guard against shock burns or flash from switch arcing Leaving equipment unattended Always shut OFF and disconnect all power to equipment Power disconnect switch mus
19. ce and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment 2000 Miller Electric Mfg Co 6 00 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller The Power of Blue
20. ce im mediately for repair See User Responsibility statement in equipment manual F Leaving Equipment Unattended Close gas supply at source and drain gas G Rope Staging Support Rope staging support should not be used for welding or cutting operation rope may burn Trademark of Proctor amp Gamble OM 877 Page 3 1 3 ARC WELDING Comply with precautions in 1 1 1 2 and this section Arc Welding properly done is a safe process but a careless operator invites trouble The equipment carries high currents at significant voltages The arc is very bright and hot Sparks fly fumes rise ultraviolet and in frared energy radiates weldments are hot and com pressed gases may be used The wise operator avoids unnecessary risks and protects himself and others from accidents Precautions are described here and in stan dards referenced in index A Burn Protection Comply with precautions in 1 2 The welding arc is intense and visibly bright Its radiation can damage eyes penetrate lightweight clothing reflect from light colored surfaces and burn the skin and eyes Skin burns resemble acute sunburn those from gas shielded arcs are more severe and painful DON T GET BURNED COMPLY WITH PRECAUTIONS 1 Protective Clothing Wear long sleeve clothing particularly for gas shielded arc in addition to gloves hat and shoes 1 2A As nec essary use additional protective clothing such as leather jacket or sleeves flame
21. e Safety precautions They will hassle free warranty in the help you protect yourself against potential hazards on the worksite We ve business made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a REGISTERED QUALITY SYSTEM Troubleshooting section that will help you Miller is the first welding figure out what the problem 15 The parts list equipment manufacturer in to be ae will then help you to decide which exact part the ISO 9001 Quality System you may need to fix the problem Warranty and service information for your particular model are also provided Miller offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local distributor Your distributor can also supply you with Welding Process Manuals such as SMAW GTAW GMAW and GMAW P Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Miller The Power of Blue TABLE OF CONTENTS SECTION 1 SAFETY R
22. efore welding check ground for continuity Be sure conductors are touching bare metal of equipment frames at connections If a line cord with a ground lead is provided with the equipment for connection to a switchbox connect the ground lead to the grounded switchbox If a three prong plug is added for connection to a grounded mating re ceptacle the ground lead must be connected to the ground prong only If the line cord comes with a three prong plug connect to a grounded mating receptacle Never remove the ground prong from a plug or use a plug with a broken off ground prong 2 Electrode Holders Fully insulated electrode holders should be used Do NOT use holders with protruding screws 3 Connectors Fully insulated lock type connectors should be used to join welding cable lengths 4 Cables Frequently inspect cables for wear cracks and damage IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and protected from hot metal and sparks 5 Terminals And Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before opera tion 6 Electrode a Equipment with output on off control contac tor Welding power sources for use with the gas metal arc welding GMAW g
23. emit toxic fumes should not be heated unless coating is re moved from the work surface the area is well ventilated and if necessary while wearing an air supplied respira tor Work in a confined space only while it is being ventilated and if necessary while wearing an air supplied respira tor Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxygen con centration dangerously Do not bring gas cylinders into a confined space Leaving confined space shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open Check to be sure that the space is safe before re entering it Vapors from chlorinated solvents can be decomposed by the heat of the arc or flame to form PHOSGENE a highly toxic gas and other lung and eye irritating prod ucts The ultraviolet radiant energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting OM 877 Page 1 atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene C Fire and Explosion Prevention Causes of fire and explosion are combustibles reached by the arc flame flying sparks hot slag or heated mate rial misuse of compressed gases and cylinders and sho
24. etween cylinder and regulator if one is required use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads Regulator outlet or hose connections may be identified by right hand threads for oxygen and left hand threads with grooved hex on nut or shank for fuel gas 5 Pressurizing Steps Drain regulator of residual gas through suitable vent be fore opening cylinder or manifold valve by turning ad justing screw in clockwise Draining prevents exces sive compression heat at high pressure seat by allowing seat to open on pressurization Leave adjusting screw engaged slightly on single stage regulators Stand to side of regulator while opening cylinder valve Open cylinder valve slowly so that regulator pressure in creases slowly When gauge is pressurized gauge reaches regulator maximum leave cylinder valve in fol lowing position For oxygen and inert gases open fully to seal stem against possible leak For fuel gas open to less than one turn to permit quick emergency shutoff Use pressure charts available from your supplier for safe and efficient recommended pressure settings on regulators Check for leaks on first pressurization and regularly there after Brush with soap solution capfull of Ivory Liquid or equivalent per gallon of water Bubbles indi cate leak Clean off soapy water after test dried soap is combustible E User Responsibilities Remove leaky or defective equipment from servi
25. igned to protect only the regulator from overpressure it is not intended to protect any downstream equipment Provide such protection with one or more relief devices Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed Remove faulty regulator from service immediately for repair first close cylinder valve The following symp toms indicate a faulty regulator Leaks if gas leaks externally Excessive Creep if delivery pressure continues to rise with downstream valve closed Faulty Gauge if gauge pointer does not move off stop pin when pressurized nor returns to stop pin after pres sure release Repair Do NOT attempt to repair Send faulty regula tors for repair to manufacturer s designated repair cen ter where special techniques and tools are used by trained personnel 2 Cylinders Cylinders must be handled carefully to prevent leaks and damage io their walls valves or safety devices Avoid electrical circuit contact with cylinders including third rails electrical wires or welding circuits They can produce short circuit arcs that may lead to a serious ac cident See 1 3C ICC or DOT marking must be on each cylinder It is an assurance of safety when the cylinder is properly han dled Identifying gas content Use only cylinders with name of gas marked on them do not rely on color to identify gas content Notify supplier if unmarked NEVER DEFACE or alte
26. ions This safety alert symbol is used with the signal words WARNING and CAUTION to call atten tion to the safety statements WARNING statements identify procedures or practices which must be followed to avoid seri ous personal injury or loss of life CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment IMPORTANT statements identify special instructions necessary for the most efficient operation of this equip ment SECTION 3 SPECIFICATIONS Rated Load For Single Phase AC np 50 60 Hertz 100 Weight 10 kW At 120 Volts 83 Amperes 240 Volts 42 Amperes Figure 3 1 Specifications 3 1 DESCRIPTION ST 108 014 Figure 3 2 Dimensional View This unit is designed to provide an adjustable load dur ing output testing procedures for any single phase 120 or 240 volts ac power source This unit is equipped with analog meters which provide simple and accurate read ings of voltage amperage and frequency SECTION 4 INSTALLATION 4 1 LOCATION Figure 3 2 CAUTION IMPROPER LIFTING OF EQUIP MENT can result in personal injury and equipment damage e Use equipment of adequate capacity to lift the unit e f using lift forks to handle this unit be sure the lift forks are long enough to extend out of the opposite side of the base Using lift forks too short will expose internal components to damage should the tips
27. lace any warranted 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 or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate 185 8 Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic
28. n electrically HOT part or grounded metal reduces the electrical resistance and could en able dangerous and possibly lethal currents to flow through the body A voltage will exist between the electrode and any con ducting object in the work circuit Examples of conduct ing objects include but are not limited to buildings elec trical tools work benches welding power source cases workpieces etc Never touch the electrode and any metal object unless the welding power source is off 1 Grounding the Equipment Arc welding equipment must be grounded according to the National Electrical Code and the work must be grounded according to ANSI 249 1 Safety In Welding And Cutting When installing connect the frames of each unit such as welding power source control work table and water cir culator to the building ground Conductors must be ade quate to carry ground currents safely Equipment made electrically HOT by stray current may shock possibly fatally Do NOT GROUND to electrical conduit or to a pipe carrying ANY gas or flammable liquid such as oil or fuel Three phase connection Check phase requirements of equipment before installing If only 3 phase power is available connect single phase equipment to only two wires of the 3 phase line Do NOT connect the equip ment ground lead to the third live wire or the equip ment will become electrically HOT a dangerous condi tion that can shock possibly fatally B
29. nen 11 7 1 Inspecci n And UBKSSO te ne dd de bd 11 72 intema Cleaning se ete eme Hadrien as 11 8 PARTS A tante 12 FIQUIe 8 1 Main ASSCMDIY e sra omen Keen A rer 12 Figure 8 2 Panel Front w Components 14 Figure 8 3 Resistor Assembly 15 OM 877 11 95 SECTION 1 SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1 1 INTRODUCTION We learn by experience Learning safety through per sonal experience like a child touching a hot stove is harmful wasteful and unwise Let the experience of others teach you Safe practices developed from experience in the use of welding and cutting are described in this manual Re search development and field experience have evolved reliable equipment and safe installation opera tion and servicing practices Accidents occur when equipment is improperly used or maintained The rea son for the safe practices may not always be given Some are based on common sense others may require technical volumes to explain It is wiser to follow the rules Read and understand these safe practices before at tempting to install operate or service the equipment Comply with these procedures as applicable to the par ticular equipment used and their instruction manuals for personal safety and for the safety of others Failure to observe these safe
30. of the lift forks penetrate the bottom of unit RESTRICTED AIRFLOW can cause improp er cooling and unit damage ENTRY OF OBJECTS THROUGH TOP can damage unit Maintain at least 12 in 305 mm of unre stricted space on all sides of the unit and keep air intakes on sides and outlet openings on top free of obstructions e Do not place tools parts etc on top of unit e Do not allow any objects to fall into top of unit e Do not place any filtering device over the intake air passages Warranty is void if any type of filtering device is used This unit is equipped with rubber casters to allow easy movement The service life and operating efficiency of this unit are reduced when the unit is subjected to high levels of dust dirt moisture corrosive vapors and extreme heat 4 2 INTERCONNECTING CORD INSTALLATION A Cord Selection It is necessary to obtain a proper 3 conductor cord for making 120 volt and or 240 volt input connections inside the unit Select a cord of adequate amperage capacity and proper wire size for the rated amperage output of the power source In most applications it should not be necessary for the required cord length to exceed 25 ft 7 6 m Table 4 1 provides a guide for selecting proper size cord for single phase power sources based on am pacity rating OM 877 Page 7 Table 4 1 Cord Size By Ampacity Rating securely onto stripped ends of conductor
31. proof apron and fire re sistant leggings Avoid outer garments of untreated cot ton Bare skin protection Wear dark substantial clothing Button collar to protect chest and neck and button pock ets to prevent entry of sparks 2 Eye and Head Protection Protect eyes from exposure to arc NEVER look at an electric arc without protection Welding helmet or shield containing a filter plate shade no 12 or denser must be used when welding Place over face before striking arc Protect filter plate with a clear cover plate Cracked or broken helmet or shield should NOT be worn radiation can pass through to cause burns Cracked broken or loose filter plates must be replaced IMMEDIATELY Replace clear cover plate when broken pitted or spattered Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck Looking at an arc momentarily with unprotected eyes particularly a high intensity gas shielded arc can cause a retinal burn that may leave a permanent dark area in the field of vision 3 Protection of Nearby Personnel Enclosed welding area For production welding a sepa rate room or enclosed bay is best In open areas sur round the operation with low reflective non combusti ble screens or panels Allow for free air circulation par ticularly at floor level OM 877 Page 4 Viewing the weld Provide face
32. r name number or other markings on a cylinder It is illegal and hazardous Empties Keep valves closed replace caps securely mark MT keep them separate from FULLS and return promptly Prohibited use Never use a cylinder or its contents for other than its intended use NEVER as a support or roller Locate or secure cylinders so they cannot be knocked over Passageways and work areas Keep cylinders clear of areas where they may be struck Transporting cylinders With a crane use a secure 5 port such as a platform or cradle Do NOT lift cylinders off the ground by their valves or caps or by chains slings or magnets Do NOT expose cylinders to excessive heat sparks slag and flame etc that may cause rupture Do not al low contents to exceed 130 F Cool with water spray where such exposure exists Protect cylinders particularly valves from bumps falls falling objects and weather Replace caps securely when moving cylinders Stuck valve Do NOT use a hammer or wrench to open a cylinder valve that can not be opened by hand Notify your supplier Mixing gases Never try to mix any gases in a cylinder Never refill any cylinder Cylinder fittings should never be modified or ex changed 3 Hose Prohibited use Never use hose other than that de signed for the specified gas A general hose identifica tion rule is red for fuel gas green for oxygen and black for inert gases Use ferrules or clamps de
33. ration See Section 1 Safety Rules For Operation Of Arc Welding Power Source for basic informa tion 1 LOADING PROCEDURE O 1 1 required connections to unit according to Section 4 2 2 Place AMPERAGE load switches in the OFF position see Section 5 3 3 Connect Load Bank cord to the ac power source Be sure to use appropriate cord when Load Bank has both 120 and 240 volt cords installed 4 Place 120 VOLT LOAD 240 VOLT LOAD selector switch in proper position see Section 5 1 5 Turn on or start the ac power source 6 Check pilot lights for proper input voltage load selection see Section 5 2 7 Rotate AMPERAGE load switches to select desired ampere load value see Section 5 3 8 Compare meter readings with ac power source Owner s Manual to check for compliance with specifications 6 2 SHUTTING DOWN 1 Rotate AMPERAGE load switches to the OFF position 2 Shut down the power source 3 Disconnect Load Bank cord from power source and place cord in the Load Bank cord storage SECTION 7 MAINTENANCE IMPORTANT Every six months inspect the labels on the unit for legibility All precautionary labels must be maintained in a clearly readable state and replaced when necessary See Parts List for part number of precautionary labels 7 1 INSPECTION AND UPKEEP Usage and shop conditions will determine the frequency and type of maintenance Inspect equipment every six months a
34. rican National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS TIBLES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 NFPA Standard 51 OXYGEN FUEL GAS SYS TEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 9 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protec tion Association Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtain able from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Ar lington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale On tario Canada M9W 1 13 booklet WELDING SAFETY BIBLIOG RAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadel phia PA 19103 14 American Welding Society Standard AWSF4 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUB STANCES obtainable from the
35. rt circuits AWARE THAT flying sparks or falling slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of sight of the goggled operator Sparks and slag can fly 35 feet To prevent fires and explosion Keep equipment clean and operable free of oil grease and in electrical parts of metallic particles that can cause short circuits If combustibles are in area do NOT weld or cut Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ven tilators If the work cannot be moved move comb ustibles at least 35 feet away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat resistant covers or shields Fire watcher must be standing by with suitable fire extin guishing equipment during and for some time after weld ing or cutting if a appreciable combustibles including building construction are within 35 feet b appreciable combustibles are further than 35 feet but can be ignited by sparks c Openings concealed or visible in floors or walls within 35 feet may expose combustibles to sparks d combustibles adjacent to walls ceilings roofs or metal partitions can be ignited by radiant or
36. s follows WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts e Shut down and disconnect Load Bank from auxiliary power source before inspecting maintaining or servicing MOVING PARTS can cause serious injury Keep clear of moving parts HOT SURFACES can cause severe burns Allow cooling period before servicing Maintenance to be performed only by qualified persons 1 Remove grease and grime from components remove moisture from electrical parts and cords 2 Check cord terminal connections Be sure that connections are clean and tight 7 2 INTERNAL CLEANING WARNING ELECTRIC SHOCK can kill e Do not touch live electrical parts e Shut down and disconnect Load Bank from auxiliary power source before inspecting maintaining or servicing HOT SURFACES can cause severe burns Allow cooling period before servicing Blow out or vacuum the dust and dirt from around the internal components Do this annually depending on the location of the unit and the amount of dust and dirt in the atmosphere If dirty or dusty conditions are present clean unit monthly The outer enclosure should be removed and a clean dry airstream or vacuum suction should be used for this cleaning operation EH E g J E 7 7 4 3 2 2051 20 207 51 U 095 0 rh U ER RE 13 Y 9 CAUTION INCORRECT SWITCH POSITIONS CAN DAMAGE INTER
37. s for both cords Cord Size AWG Ampacity Of Cord 18 10 4 Insert cords up through strain reliefs in bottom of 14 18 front access opening Be sure cords are in cor rect locations for 120 volt and 240 volt connec ha tions see unit nameplate and Figure 4 1 10 30 IMPORTANT Do not remove existing leads from ter minal studs 6 50 3 16 5 Remove only the outside nut from each terminal 2 95 board stud for 120 and 240 volt connections Re Cord sizes are based on National Electrical Code 1984 Edition move top nut from ground terminal stud see specifications for allowable ampacity for not more than two ther Figure 4 1 moset or thermoplastic insulated current carrying copper conduc tors in a cord see Article 400 in NEC for specific information 6 Install conductor ring terminals onto studs as in dicated in Figure 4 1 and secure with nuts re B Cord Connections moved in Step 5 Using proper cords of desired length make connections to the load bank as follows 7 Secure cords by tightening strain relief clamp screws 1 Remove front access panel from unit see Figure 5 1 8 Reinstall front access panel onto unit 2 Strip cord jacket back approximately 5 in 127 9 Obtain and install a proper plug that matches the mm and separate conductors strip 1 4 in 6 mm power source receptacle onto remaining end of of insulation from end of each conductor cords 3 Obtain ring terminals of proper cap
38. signed for the hose not ordi nary wire or other substitute as a binding to connect hoses to fittings No copper tubing splices Use only standard brass fit tings to splice hose Avoid long runs to prevent kinks and abuse Suspend hose off ground to keep it from being run over stepped on or otherwise damaged Coil excess hose to prevent kinks and tangles Protect hose from damage by sharp edges and by sparks slag and open flame Examine hose regularly for leaks wear and loose con nections Immerse pressured hose in water bubbles in dicate leaks Repair leaky or worn hose by cutting area out and splic ing 1 2D3 Do NOT tape 4 Proper Connections Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator Except for hydrogen crack valve momentarily pointing outlet away from people and sources of ignition Wipe with a clean lintless cloth Match regulator to cylinder Before connecting check that the regulator label and cylinder marking area and that the regulator inlet and cylinder outlet match NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas Tighten connections When assembling threaded con nections clean and smooth seats where necessary Tighten If connection leaks disassemble clean and retighten using properly fitting wrench Adapters Use a CGA adapter available from your sup plier b
39. t be available near the welding power source F Protection For Wearers of Electronic Life Sup port Devices Pacemakers Magnetic fields from high currents can affect pacemak er operation Persons wearing electronic life support equipment pacemaker should consult with their doctor before going near arc welding gouging or spot welding operations 1 4 STANDARDS BOOKLET INDEX For more information refer to the following standards or their latest revisions and comply as applicable 1 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 2 NIOSH SAFETY AND HEALTH IN ARC WELD ING AND GAS WELDING AND CUTTING ob tainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 3 OSHA SAFETY AND HEALTH STANDARDS 29 1910 obtainable from the Superinten dent of Documents U S Government Printing Office Washington D C 20402 4 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from the Ameri can National Standards Institute 1430 Broad way New York NY 10018 OM 877 Page 5 5 ANSI Standard 441 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 6 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROC ESSES obtainable from the Ame
40. y label the label should also be ordered BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 877 Page 14 Item No Part No 106 667 059 800 059 726 059 724 059 728 059 725 059 727 059 724 070 270 106 669 106 666 059 779 059 797 059 798 106 668 Description Quantity Figure 8 3 Resistor Assembly Fig 1 3 BUS BAR connecting resistors ea nl 2 RESIO TOR SPA Baa ee nr ee er Gee ees 4 INSULATOR End ii ee ne ted ote a ha 48 48 INSULATOR SUDO baba iia 20 RING ts sao did Bee een 20 INSULATOR SUPPO senken A ac 28 RING TEAMING arten ee a 28 BUS BAR connecting resistors 6 BUS BAR connecting resistors 2 BUS BAR connecting resistors sn da A 6 RESISTOR taut nant es tela a diam Dot Ca ou 6 BESIS EOS a ae te en Cole te Sl de A 4 RESISTOR TOA 10 BUS BAR connecting resistors 2 fC x D EN yo A gt AN N gt NN gt gt D 2 BLM aN A AN lt AR AN a gt gt 2 wer nee K y ER gt e Ne gt S ENG END NS AL KO KE AR Ne ww SS E NN 9 SEVEN s SY 4 EN Sy WW A N WS gt AN 4
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