Miller Electric 152 Welding System User Manual
Contents
1. AE OR 16 4 4 Weld Process Switch 16 4 5 Arc Switch ics EA SE ERU ST Sie REM 17 4 6 Power Switch And Pilot 17 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 18 5 1 Routine Maint hianee s i rye sede nat ane neo a endow gts 18 5 2 Measuring Input Capacitor 19 5 3 Troubleshooting Re e RE Ra eee es Pee e RARE 20 SECTION 6 ELECTRICAL DIAGRAMS 22 SECTION 7 SELECTING AND PREPARING TUNGSTEN ELECTRODE 24 7 1 Selecting Tungsten Electrode 24 7 2 Preparing Tungsten For AC Or DC Electrode Positive Welding 25 7 3 Preparing Tungsten For DC Electrode Negative DCEN Welding 25 SECTION 8 GUIDELINES FOR TIG WELDING GTAW 26 851 Positioning The Torch sn Ease 26 8 2 Torch Movement During Welding 26 8 3 Positioning Torch Tungsten For Various Weld Joints2. Of Mae de F19 9 2 s MODULE diode oce grenier EE utile Tarred ee E TETEE TT 141515 STRIP polyest gl lam 187 500 812 Ti nus od edidi ios 126 026 LABEL warning electric shock can kill Li oe et 119 943 STRIP polyest gl lam 187 x 500 x 6 500 1 140 380 STRIP polyest gl lam 187 500 x 8 687 1 outs Tecta Zl 130 794 STABILIZER 1 Ene rA 131866 i epe re exu EOS X GU wae ee dee 1 PAP 019 663 MOUNT nprn 15 16 OD 4 4 ar HD1 156 149 TRANSDUCER current 1 HD1 124 684 TRANSDUCER current 300A module supply 1 pid bei PLG10 130 204 CONNECTOR amp SOCKETS consisting of 1 1 ei beUa diri Sa 114 066 CONNECTOR rect skt 20 14ga Amp 350536 1 3 8 cetus Td Ice 151 585 TRANSFORMER pwr 1 AR eer 141 669 TRANSFORMER pwr main 325 1 e H2 us 139 203 RESISTOR WW fxd 30W 8K 1 C R253 iis 139 203 RESISTOR WW fxd 30W 8K 2
3. 1 URS DC enti FM 156 246 MOTOR fan 120 230V 2600RPM w 36V sec consisting of 1 usi RC6 185409 CONNECTOR amp PINS consisting of 1 Lebe i 114 656 CONNECTOR rect pin 24 18ga 8 FM 170 692 MOTOR fan 230 460V 2600RPM w 36V sec consisting of 1 ERE RC11 165 895 CONNECTOR amp PINS consisting of 1 ONE 147 996 CONNECTOR rect skt 22 18ga 9 per se 146 238 BRACKET mtg fan dores Los eon quts aa NE 151 484 HEAT SINK pwr module 1 eer dd 141 423 HEAT SINK pwr 0 1 s Q1 4 149207 KIT transistor mosfet 4 4 Mt MES D5 xcu 149 215 KIT diode fast 1 0 TP2 032 810 THERMOSTAT NC see TW SR1 149 218 KIT rectifier integ 100 1 ied es SR1 149 217 KIT rectifier integ 100A 1 vex darius VOM1 164849 MODULE varistor capacitor 4 400 joule 1620 1980VDC 1 Las deis PC2 151284 CIRCUIT CARD interconne
4. 27 SECTION9 PARTS LIST mille ERE es ore sane EDEN Reim eas m eR 28 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage 4 Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away IE 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 e Do n
5. TWNOLLAO QuvOB 69d 803 gt gt lt lt Z lt 9 004 2 gt 7 lt 6 06524 lt 5 9 808 gt gt 22 lt lt 8 050 1 1 1 928 225 244 lt lt 1 0824 69d T 304 gt gt py lt 9 7 lt lt 8 124 v 928 gt P 9 OSOM 0GOM lt lt onm FEU gt gt ug X SOS 504 LU M AN 1 80 DZ lt E 06 2 69 1 6 4 gt p lt 1 06 A9 gig 7 as Ll g S EN gt 9 OP 1nO INNI m lt a oO 3 acr gt Tan rg ONWWOO 22 1 gt Nyd GIE gt 7 po TAB gt gt 2 1 LNawusnrav 3LON PERDIDERIT gt x 6 ec e Isy lt Z S 440 d a z 19 A c9 LIN 2 05 MY19 8 0 78 MS c 3 E wo 7 8 m m 2 104 gt sv lt 1 99 I 1 o CM 1 E NO em 90 G 7 y lt 8 5 HOLIVINCO 5 IY ii d E 8 124 gt Z es 8 ua 2 3 9 IL PI LI L AOLIYINCO vA 94 62 ysv lt 9 6 rate Lol led 8974 8294 9 99 gt gt 2 T H 9 lt lt Sse G9 1d GO4 LOM id Zad E O E s Fh zo 19 4 08 WEN SD gt 3 T M lt uso 5 3 z s T T 26 7 LL 1 y lt lt 2 8 8 te Bae amp d By d a vH ilH Y Y Y Y Y Y LH KD mE 4 9 G gt 3 gor e LH gt 97 de zz na ED m
6. 134 731 CONNECTOR circ pin push in 14 18ga Amp 213603 1 079 739 CONNECTOR circ clamp str rlf 703 max cable OD Amp 206322 2 or Sih hat Gilera etd rufi 143 922 CONNECTOR circ clamp str rif 453 max cable OD Amp 206070 3 ien o 168 755 CASE SECTION bottom rear 1 OB as 140 621 CASE SECTION bottom rear 1 When ordering a component originally displaying a precautionary label the label should also be ordered Included with Interconnecting Circuit Card PC2 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 206 Page 30 Quantity Item Dia Par No Mkgs No Description 152 175 Figure 9 2 Module Power amp Diode Fig 9 1 Item 26 amp 27 M CTI 093 085 CAPACITOR polye MF 0047 1000 Thes set 1 158 540 MODULE pwr consisting of 1 BOUE 170 702 MODULE pwr consisting of 1 eie ated 156 247 BLADE fan 6 in 4wg 30deg 252 bore CCW 1 Sofern IDA Eie 170 706 KIT fan blade consisting of 1 mas 605 525 NUT 312 24 stl elastic stop
7. RENNES MD NER ATE NR RE 9 2 2 Volt Ampere Curves 2 9 2 3 Duty Cycle And 10 SECTION 3 5 1 11 3 1 Selecting 11 3 2 Selecting And Preparing Weld Output Cables 11 3 3 Weld Cable Size renien eda sas ros eo RO SERDERBDRIBDIVRLIEDACRESREDES 11 3 4 Connecting To Weld Output Receptacles 12 3 5 Remote 14 Receptacle Information And Connections 12 3 6 Remote 14 Socket Information 13 3 7 Connecting Input Power To 152 Models 13 3 8 Electrical Service Guide For 152 Ampere Models 13 3 9 Connecting Input Power To 175 Models 14 3 10 Electrical Service Guide For 175 Ampere Models 14 SECTION 4 OPERATION x mRIREEREK BI barnes 15 4 1 COMMONS c ees tei eode de cx vC v exile ex ees 15 4 2 Output Contactor Switch zen nee xe RR REA NR EE e 15 4 3 Amperage Controls
8. 206 13 3 9 Connecting Input Power 175 Models Tools Needed F0 5 16in Have only qualified persons make this installation 1 Line Disconnect Device Of Proper Rating 2 Input Conductors 3 Grounding Conductor Select size and length using Sec tion 3 10 Conductor rating must comply with national state and local electrical codes Strip 3 8 in 10 mm insulation off conductors 4 Strain Relief Connector Remove wrapper and insert con ductors 5 Input Terminal Block 6 Line Terminals 7 Welding Power Source Ground Terminal Connect grounding conductor to ground terminal first Then connect input conductors to line terminals Tighten strain relief connector 8 Disconnect Device Ground Terminal Install and connect grounding conductor and input conductors in conduit or equivalent to deener gized line disconnect device Connect grounding conductor first then line input conductors Be sure grounding conductor goes to an earth ground Reinstall wrapper 9 Overcurrent Protection Select type and size using Section 3 10 Install into deenergized line disconnect device fused disconnect switch shown Ssb2 4 1 94 ST 145 667 B SA 145 666 C 3 10 Electrical Service Guide For 175 Ampere Models Input Voltage 460 Input Amperes At Rated Output 74 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 10 Min
9. 206 141 754F October 1999 Miller TIG GTAW Welding The Power of Blue Stick SMAW Welding Description 55 Arc Welding Power Source 152 Model Phase 175 Maxstar 152 And 175 OWNER S MANUAL Visit our website at www MillerWelds com 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 BI Il E tradition They re just as committed to providing equipment and service oR WARRANTY 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 the 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 yo
10. mm lt lt 8 062 gt a lt lt L 0994 Dr SK 9 090 0 i Dar SK gt gt 2 lt lt 0924 9 228 294 6 198 1 128 8 94 1 294 8979 8295 9079 6209 19727 198 13d 2 62 1 828 L S98 98 994 9 628 6 858 lt 11 994 lt 21 625 lt RC2 14 lt RC3 10 lt RC3 2 9 828 1 928 828 6 82 L 894 894 11 198 91 198 01 128 S 198 21 198 198 81 198 v ZEI gt gt lt lt 06 0908 01140 QavO8 3134 69 ld 112 lt ino 434 gt gt ONVNNOD 2 gt 7aNvd 2 77 M gt AN3HLSNTOY o OVUSdNV 37 gt 2 11 228 E dd M Y N m g ASI ASI 8 8 a S X LS 5 46 9 See 5 166 403 2 1N3XANI 310438 Le 3 N ite T LL 5 S ium D M 2 193 O Li 2 D LL LH 119794 16 0 01 O 1l OM 206 Page 22
11. tions 3 7 or 3 9 Check for proper input and output connections see Sections 3 2 3 4 and 3 7 or 3 9 Erratic or improper weld output Tighten all welding cable connections see Sections 3 2 and 3 4 Check for proper size and type of cable see Section 3 2 Check for proper input and output connections see Sections 3 2 3 4 and 3 7 or 3 9 Replace electrode see Section 7 Arc not forming when using Lift Arc Check electrode and workpiece clean as needed to allow good contact Fan motor FM does not run Check and clear blocked fan blade be sure blade is secure on shaft Have Factory Authorized Service Station Service Distributor check fan motor FM Wandering arc poor control of arc di rection Reduce gas flow rate Select proper size tungsten see Section 7 1 Properly prepare tungsten see Sections 7 2 and 7 3 Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Increase postflow time Check and tighten all gas fittings Water in torch Refer to torch Owner s Manual for part s requiring replacement and repair torch as necessary OM 206 Page 20 Notes OM 206 Page 21 SECTION 6 ELECTRICAL DIAGRAMS BAILISOd 3 11 93 AJNO SNOILVNINA31 31VOIONI SH3BWN HA 19 AAI 2 838 22 77 K 6 0coH
12. AVE FE A EJ 2 5 A au za 2 2 7 55 0 1 3ALV93N 4 7 o S f fg AO 19 d 4 4 ou T 29 Lu SC 170 697 OM 206 Page 23 Figure 6 2 Circuit Diagram For 175 Model SECTION 7 SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw 7 97 NOTE gt contamination of tungsten electrode For additional information see your distributor for a handbook on the Gas Tungsten Arc Welding GTAW process Wear clean gloves to prevent 7 1 Selecting Tungsten Electrode Amperage Range Gas Type Polarity Electrode Diameter DC Argon Electrode Negative Straight Polarity DC Argon Electrode Positive Reverse Polarity AC Argon Using High Frequency AC Argon Balanced Wave Using High Freq Pure Tungsten Green Band 010 Up to 15 Up to 15 Up to 10 020 5 20 5 20 10 20 040 15 80 10 60 20 30 1 16 70 150 10 20 50 100 30 80 3 32 125 225 15 30 100 160 60 130 1 8 225 360 25 40 150 210 100 180 5 32 360 450 40 55 200 275 160 240 3 16 450 720 55 80 250 350 190 300 1 4 720 950 80 125 325 450 250 400 2 Thorium Alloyed Tungsten Red Band 010 Up to 25 i Up to 20 Up to 15 020 15 40 15 35 5 20 040 25 85 20 80 20 60 1 16 50 160 10 20 50 150 60 120 3 32 135 235 15 30 130 250 100 180 1 8 250 400 2
13. Input Conductor Size In AWG Kcmil 14 Max Recommended Input Conductor Length In Feet Meters 443 135 Min Grounding Conductor Size In AWG Kcmil 14 Reference 1993 National Electrical Code NEC S 0092J OM 206 Page 14 SECTION 4 OPERATION 4 1 Controls 42 DE v o 1 Adjustment Control Wy QZ 42m 2 Amperage Control Switch 3 Output Contactor Switch 4 Lift Arc Switch 5 Weld Process Switch 345 6 6 Power Switch 7 Pilot Light a CJ C ST 152 127 A 4 2 Output Contactor Switch fe 1 Output Contactor Switch Use switch to select way of control ling output For front panel control place switch in On position For remote control place switch in Remote 14 position see Section 3 5 OX Weld output receptacles are energized when switch is On and Power is On Ref SC 157 579 A OM 206 Page 15 4 3 Amperage Controls A AMPERAGE ADJUSTMENT AMPERAGE EXAMPLE Of Combination Remote Amperage Control CG pns g AMPERAGE OUTPUT Set Switches Set Control AMPERAGE ADJUSTMENT 1 Amperage Adjustment Control Use control to select weld amper age Amperage may be adjusted while welding 2 Amperage Control Switch Use switch to select way of
14. c U gt 1 Z 2222 7 22727 2 2 Z 4 Tilt torch Move torch to front of pool Repeat process Tungsten With Filler Rod 75 Welding direction gt 15 ay Li ea 1 Z ZZZ amp 1 7 2 4 Tilt torch Add filler metal Ss 5 Z 222 A 2225222272 Remove rod Move torch to front of pool Repeat process ST 162 002 B OM 206 Page 26 8 3 Positioning Torch Tungsten For Various Weld Joints Butt Weld And Stringer Bead 70 2 20 20 Joint 70 20 10 40 Lap Joint 2 20 30 Corner Joint 90 K ST 162 003 5 0792 206 27 SECTION 9 PARTS LIST Hardware is common and not available unless listed 18 Is Supplied with 152 Model only ST 145 668 J Figure 9 1 Main Assembly 175 Model Illustrated OM 206 Page 28 Quantity Item Dia Part Mode No Mkgs No Description 152 175 Figure 9 1 Main Assembly esrb atre tetur 195 585 HANDLE rubberized carrying Ti aus uad ous reset atus ne 134 327 LABEL warning general precautionary deest aL heben 1163781 WRAPPER dk teeta 1 XL Mut 1603 7822 WRAPPER x n
15. control ling amperage adjustment For front panel control place switch in Panel position For remote control place switch in Remote 14 position see Section 3 5 See Example below 3 Remote Foot Control 4 Remote Hand Dial 5 Fingertip Control Unit Minimum Control Setting 80 A Adjust Remote Control ST 159 059 S 0769 4 4 Weld Process Switch PROCESS a 1 GTAW MAW START PROCESS 1 Weld Process Switch Use switch to select type of weld output current Use GTAW position for Gas Tungsten Arc Welding Use SMAW position for Shielded Metal Arc Welding Switch position determines the op eration of the Lift Arc switch see Section 4 5 OM 206 Page 16 NOTE 7 Lift Arc switch must be Off position when using High Frequency unit with this welding power source or when using the SMAW welding process 4 5 Lift Arc Switch LIFT ARC RE 1 ON O OFF 1 2 Seconds Do NOT Strike Like A Match 1 Lift Arc Switch Use switch to select Lift Arc On or Off With Lift Arc On start an arc in GTAW welding as follows 2 GTAW Electrode 3 Workpiece Touch tungsten electrode to work piece at weld start point hold elec trode to workpiece for 1 2 sec onds and slowly lift electrode An arc will form when electrode is lifted Normal open circuit vol
16. d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces LES FUMEES LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimenta tion d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du fabricant concernant les m taux les consomma bles les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxy provoquant des blessures ou des accidents mortels S assu rer que l air de respiration ne pr sente aucun danger e pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder
17. 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 e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding Eq FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 206 Page 2 a BUILDUP OF GAS can injure or kill Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the
18. humides dans les endroits confin s ou l on risque de tomber e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e Sil utilisation d une source lectrique courant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des cables us s endommag s de gro
19. of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 Symbol Usage crea abet etat Rx Aa 1 1 2 Arc Welding Hazards 2 1 1 1 1 8 Additional Symbols For Installation Operation And Maintenance 3 1 4 Principal Safety Standards 74 3 1 5 EME Informatior ate A 4 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5 1 1 Signification des symboles 5 1 2 Dangers relatifs au soudage larc 5 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement otla maintenance m rae rem Fed vie Ces aa I E E Pea es 7 1 4 Principales normes de 8 1 5 Information sur les champs lectromagn tiques 8 SECTION 2 5 5 9 2 15 SpecifiCatiolis cep
20. 5 40 225 360 160 250 5 32 400 500 40 55 300 450 200 320 3 16 500 750 55 80 400 500 290 390 1 4 750 1000 80 125 600 800 340 525 Zirconium Alloyed Tung sten Brown Band 010 Up to 20 Up to 15 020 X 15 35 5 20 040 20 80 20 60 1 16 50 150 60 120 3 32 gt 130 250 100 180 1 8 225 360 160 250 5 32 i 300 450 200 320 3 16 400 550 290 390 1 4 gt 600 800 340 525 Typical argon shielding gas flow rates are 15 to 35 cfh 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 OM 206 Page 24 7 2 Preparing Tungsten For AC Or DC Electrode Positive Welding 1 Tungsten Electrode 2 Balled End A Understand follow 1 safety symbols at start of Section 8 1 before preparing tungsten 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 Section 7 1 or a dc 2 electrode positive amperage e E 1 1 2 Times _ Electrode Diameter Ref S 0161 7 3 Preparing Tungsten For DC Electrode Negative DCEN Welding 1 Tungsten Electrode 2 1 2 2 Grind of tungsten on fine grit hard abrasive wheel before weld ing Do not use wheel for other jobs 2
21. ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e lf earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use a
22. L 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 O MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tron
23. Overheating minutes Let fan run for 15 minutes When overheated thermostat opens output stops and cooling fan keeps running Start welding rduty1 5 95 SB 121 591 B SB 144 507 B ST 157 356 B OM 206 Page 10 SECTION INSTALLATION 3 1 Selecting A Location 1 10 in 254 mm Open Space On Right Side And Rear Of Unit For Good Airflow 2 Lifting Handle Use handle to move unit 3 Rating Label Locate unit near correct input power supply AA Ref SA 145 666 1 Weld Output Cable Determine total cable length in weld circuit and maximum welding am peres Use Section 3 3 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 hole size for connecting to work clamp electrode holder or wire feeder 3 Insulated Electrode Holder Example Install according to manufacturer s Total Cable instructions Length In Weld Circuit 20 ft 6m 4 Work Clamp Install onto work cable 5 Dinse Type Connector Tools Needed Install onto weld cable CL Te eu sb6 2 5 94 S 0656 3 3 Weld Cable Size Total Cable Copper Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft TOO ECD ny Oribess 45 m 60 m 70 m 90m 105m 120m
24. PLATE meter T saad AG scie es pev Ee 166881 BLANK meter nameplate backing dz d PE EE 097 922 KNOB pointer Le 48 R4 073 562 POTENTIOMETER C sltd sft 1 T 2W 10K ohm d meu PO osse eke eects 151533 ze PANEL front ie EOET ERES 1 ADR I 146 333 PANEL 1 DO ae Gries 161 098 BUS BAR 1 1 Gn E 134 756 LABEL warning electric shock can kill 1 527 C12 135 286 CAPACITOR Pre terere oU ed D eae Y uw Date 135289 CAPACITOR Liebe PREDA T 22d 54 C14 141 524 LEAD ASSEMBLY elect 54 C15 141 525 LEAD ASSEMBLY elect Ti pee 1 54 16 141 522 LEAD ASSEMBLY elect Tox 54 C17 141 523 LEAD ASSEMBLY elect Tied 235955 rd id RC7 143 976 CONNECTOR w SOCKETS consisting of T etd Mc 079 534 CONNECTOR circ skt push in 14 18ga Amp 66358 6 14 14 prie 134 734 CONNECTOR circ 14 plug Amp 213571 2
25. RE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL 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 ANY AND EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED 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 com
26. RI ue 136 076 RESISTOR WW fxd 30W 200 ohm T e LE es AR e ied 141 422 INSULATOR flat pack LR Slt ous 090 328 SWITCH tgl DPST 40A 600VAC 1 OM 206 Page 29 Quantity Item Dia Par Model No Mkgs No Description 152 175 Figure 9 1 Main Assembly Continued ae ed evi PLG11 115094 CONNECTOR amp SOCKETS consisting of 1 TROPPO 113 746 CONNECTOR rect skt 24 18ga Molex 39 00 0038 4 RC11 115090 CONNECTOR amp PINS consisting of 1 EHE 114656 CONNECTOR rect 24 18ga Molex 39 00 0040 4 aie Wi ata 047 838 BLANK snap in 1 000mtg hole 1 38 S1 091 441 SWITCH tgl 3PST 40A 600V 1 Base ulus 148 297 NUT speed type 10 32 2 4 5 2 40 146 684 INSULATOR switch 1 oa od doe os CR1 106 462 RELAY 24VDC dores NAMEPLATE order by model and serial number lisse 43 PET uus 157 958 LIGHT ind white lens 28V Poasi S2 5 120 376 SWITCH rocker SPDT 4 250VAC 4 4 AD AN ERA HA 166 883 NAME
27. SINK diode module 1 ru tS 140 622 HEAT SINK diode module 1 EV R9 098 324 RESISTOR WW fxd 25W 5 ohm 1 sue cones sa HD Ate tat 098 324 RESISTOR WW fxd 25W 5 ohm 1 usn dts D12 151 431 KIT diode ultra fast recovery las 1 C9 10 098325 CAPACITOR polyp film 027uf 630V 21 225 22 775 1 129 552 THERMOSTAT NC Timer A When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 206 Page 32 Notes 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 pre
28. Welding 10 To 60 60 Thru 100 Amperes Duty Cycle Duty Cycle 10 Thru 100 Duty Cycle 4 4 2 1 3 1 0 2 0 3 2 0 3 0 2 4 0 Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least than 300 circular mils per ampere S 0007 D OM 206 Page 11 3 4 Connecting To Weld Output Receptacles 1 Positive Weld Output Receptacle 2 Negative Weld Output Receptacle 3 Connector For Electrode Positive DCEP connect work cable connector to negative receptacle and elec trode holder cable connector to positive receptacle For Electrode Negative DCEN reverse cable connections Align keyway insert connector and turn clockwise Ref SC 140 373 Ref ST 152 126 1 Remote 14 Receptacle RC7 See Section 3 6 2 3 Plug 4 Threaded Collar To connect to receptacle align keyway insert plug and tighten threaded collar Rear Panel 507 1 5 94 ST 801 174 Ref S 0004 A 5 0750 Ref ST 141 127 OM 206 Page 12 3 6 Remote 14 Socket Information REMOTE 14 Socket Socket Information A 15 volts OUTPUT B Contact closure to A completes 15 volts de contactor control circuit Output command reference 0 to 10 volts dc depending on setting of Amperage Adjustment control R4 A V AMPERAGE D Remote control circuit common VOLTAGE 3 E Input command
29. amais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 2 Risque D INCENDIE OU f D EXPLOSION Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un eng
30. cos eeu 133 405 NUT speed 10 24 flat type rectangular 1 2 anc dA nuo 130 215 PLATE output rear panel 1 140 373 PLATE output rear panel 1 15 Neg Pos 129525 RECEPTACLE twlk insul fem Dinse type 50 70 series 2 2 dL Re RES dee dU 129 527 CONN twlk insul male dinse type 50 series 2 2 lose 145 743 LUG univ w scr 600V 2 14 wire 1 tas csdser zri tasna 010916 CONNECTOR clamp cable 750 10 22 le 120 484 CORD SET 250V 6 50P 12ga 3 c 8ft 1 sete 9 arts is TET uus 147 386 BLOCK term 70A 1 est E deut 147 255 BRACKET mtg terminal block 1 Lead xr tee Dee 119 757 BAR support heat sink bottom dose 71 HIVE 126 372 STRIP polyest gl lam 187 250 625 des POS wae bic dudes 140 626 STRIP polyest gl lam 187 500 2 250 T use iil A curse e 128 803 BAR support heat sink top dne Al LED os CTI 150925 TRANSFORMER current desde os AOI M Fig 9 2 MODULE power
31. cting 1 Sou CE PC2 167 368 CIRCUIT CARD interconnecting 1 tethered sale PLG6 115 092 CONNECTOR amp SOCKETS consisting of 1 113 746 CONNECTOR rect skt 24 18 ga 8 PLG11 163467 CONNECTOR amp SOCKETS consisting of 1 147 995 CONNECTOR rect skt 24 18 ga 9 cd a rahe aie 153 178 LABEL warning exploding parts etc 1 24525 VR4 004 113 VARISTOR 40 joule 390VDC E 1415 Supplied with 152 Model only E Hardware is common and not available unless listed ST 145 796 D Figure 9 2 Module Power amp Diode 175 Model Illustrated OM 206 Page 31 Quantity Model Item Dia Part a e No Mkgs No Description 152 175 Figure 9 2 Module Power amp Diode Fig 9 1 Item 26 amp 27 Continued R10 030 839 RESISTOR WW fxd 5W 220 ohm et DM1 151 479 MODULE diode consisting of 1 bt TL weet 5 DM1 140 492 MODULE diode consisting of 1 05 6 151 229 KIT diode ultra fast recovery Te von t TOS Cose 151 470 HEAT
32. d before working on unit Check input capacitor s Measure the dc voltage across the positive and negative terminals until voltage drops to near 0 zero volts Proceed with job inside unit Reinstall wrapper when finished Tools Needed C P 5 16 in ST 153 136 B OM 206 Page 19 5 3 Troubleshooting gt e Gs Trouble Remedy No weld output unit completely inop erative Be sure Power switch is On see Section 4 6 Secure power cord plug in receptacle 152 model see Section 3 7 Be sure line disconnect switch is On see Section 3 9 Check line fuse s and replace if necessary Reset circuit breakers see Sections 3 7 or 3 9 Check for proper input power connections see Sections 3 7 or 3 9 No weld output fan motor FM running and pilot light on Check position of Output Contactor switch see Section 4 2 Thermostats TP1 and or TP2 open overheating Allow fan to run thermostat s closes when unit has cooled see Section 2 3 Low weld output with no control Check position of Amperage Control switch see Section 4 3 Have Factory Authorized Service Station Service Distributor check control board PC1 Limited output and low open circuit voltage Check incoming power for correct voltage Replace line fuse if open or reset circuit breaker see Sec
33. des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n cessaire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 206 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev e Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds F LE SOUDAGE peut provoquer un TER incendie ou une explosion Le soudage effectu sur des cont
34. di te ted EVER Xe e pne EH MESS 1 fe OS uu iens 1 164 619 CIRCUIT CARD control 1 1 ee Meine teens PLG1 2 131 052 CONNECTOR amp SOCKETS consisting of 2 2 SNA NE NES 113746 CONNECTOR rect skt 24 18ga Molex 39 00 0038 16 16 SENE PLGS 131 056 CONNECTOR amp SOCKETS consisting of 1 1 Die EB ARS babe 113 746 CONNECTOR rect skt 24 18ga Molex 39 00 0038 14 14 PLG5 130 203 CONNECTOR amp SOCKETS consisting of 1 1 m 113 746 CONNECTOR rect skt 24 18ga Molex 39 00 0038 12 12 141 690 GROMMET scr 8 10 panel hole 281sq 197 high 6 6 140 627 INSULATION PC card 1353201 Xe 151280 BRACKET mtg PC card 1 141 520 BRACKET mtg 1 Auer 0 QT Lis 151 281 CAPACITOR elctit 1600uf 400VDC 1 1 2 151 281 CAPACITOR elctit 16000 400VDC 2 Nn ERE 006 426 CLAMP capacitor 2 000dia Torce ATE 153 178 LABEL warning exploding parts 1 see Es 136 190 NUT speed type 10 32 2 4
35. eneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de de soudure La projection d tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir
36. face 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 replace 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 Years Labor Original main power rectifiers Inverters input and output
37. ic and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 206 Page 4 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles 4 ldentifie un message de s curit particulier Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc Les symboles pr sent s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et suive
38. ic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection 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 OM 206 Page 3 1 5 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electr
39. in d une capacit appropri e pour Soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil nn i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage Ne pas obstruer les passages d air du poste LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s gt amp e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage 5 3 DES ORGANES MOBILES peuvent provoquer des blessures e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement e
40. l Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI 487 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re search Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectrique
41. les normes de s curit e Brancher le cable sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES T peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 206 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air ho
42. mal 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 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 A
43. mensions Length 16 1 2 in 419 mm 120A 230 Volts AC 50 60 Hz 152 25 Volts DC 1 150 95 Single Phase ia eee 100 Duty Cycle 27 1 0 5 0 1 0 0 9 241 Height 8 203 mm Length 16 1 2 in 419 mm 140A 460 Volts AC 50 60 Hz 175 256VoltsDC 1 175 95 Three Phase ae put m o 5 100 7 4 1 0 0 4 0 9 241 Height 10 in 254 mm While idling 2 2 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between the curves shown A 152 Model B 175 Model 100 100 90 90 80 80 70 70 60 P eo 50 50 Q 40 940 30 30 20 20 BR 0 0 aS D 0 50 100 150 200 250 0 50 100 150 200 250 300 DC AMPERES DC 5 ssb1 1 10 91 SB 151 604 SB 143 476 OM 206 Page 9 2 3 Duty Cycle And Overheating 100 Duty Cycle At 120 Amperes For 152 Models 140 Amperes For 175 Models Continuous Welding A 152 Model 300 200 250 150 200 i o Ji 2 3 mmm kaj gt M 10 15 20 25 30 40 50 60 70 80 90 100 DUTY CYCLE p Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit void warranty B 175 Model 20 25 30 40 50 60 70 80 90 100 DUTY CYCLE
44. mologu DES PIECES CHAUDES peuvent voquer des br lures graves e pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma 96e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques Ne j
45. n approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e 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 OM 206 Page 1 ARC RAYS burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others f
46. n place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences Lerayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appa reil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des Sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi court
47. or tungsten can become contami nated causing lower weld quality 2 1 2 Times Electrode Diameter 1 Stable Arc 2 Flat Diameter of this flat determines Sa amperage capacity 3 Grinding Wheel 5 4 Straight Ground 75 Ideal Tungsten Preparation Stable Arc 1 Arc Wander 2 Point 1 3 Grinding Wheel 4 Radial Ground 2 55 4 Wrong Tungsten Preparation Wandering Arc Ref S 0161 Ref S 0162 OM 206 Page 25 SECTION 8 GUIDELINES FOR WELDING GTAW 8 1 Positioining The Torch A Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Tungsten Electrode Select and prepare tungsten according to Sections 7 1 and 7 2 or 7 3 Tungsten extension is the distance the tungsten extends out gas cup of torch Arc length is the distance from the tungsten to the workpiece As a general guide start with an extension and arc length equal to diameter of tungsten ST 161 892 8 2 Torch Movement During Welding Tungsten Without Filler Rod Welding direction 1 7 gt 75 gt lt
48. ot touch live electrical parts Wear dry hole free insulating gloves body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use 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 if present on unit e Disconnect input power or stop engine before installing or Servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som nd 5 97 e i This group of symbols means Warning Watch Out possible
49. plete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment sovice and Miller Electric Mfg Co Replacement Parts An Illinois Tool Works Company 1635 West Spencer Street Training Schools Videos Books Appleton WI 54914 USA ae International Headquarters USA Technical Manuals Servicing Information USA Phone 920 735 4505 Auto Attended and Parts USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 Circuit Diag rams European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Welding Process Handbooks www MillerWelds com Contact the Delivering Carrier for File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department Miller The Power of Blue PRINTED IN USA 2000 Miller Electric Mfg Co 6 00
50. r accessories Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit nn LU OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle a Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit ee STATIC ESD can damage PC boards 79 e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 22 N MOVING PARTS can cause injury Keep away from moving parts Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do 50 e Do not point gun toward part of the body other people or any metal when threading welding wire 5 1 4 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 Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami F
51. 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 2Wire Feeder Motor Driven Guns w exception of Spoolmate 185 amp Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HFUnits Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic 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 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 nor
52. rom flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e 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
53. s haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 206 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 SPECIFICATIONS NOTE Unless otherwise noted the 175 model is shown throughout this manual 2 1 Specifications Maximum Rated Welding Amperage iren Amperes Input at z Overall Model Output Range DE Rated Load Output KVA Kw Weight Di
54. s que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e Encasd iterf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez dis tance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 206 Page 7 1 4 Principales de s curit Safety in Welding and Cutting norme ANSI 249 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrica
55. signal potentiometer wiper or 0 to 10 volts dc K Chassis common The remaining sockets are not used 3 7 Connecting Input Power To 152 Models Have only qualified persons make this installation 1 Line Disconnect Device Of Proper Rating 2 230 Volts AC Wall Receptacle 3 Input Conductors 4 Grounding Conductor Select size and length using Sec tion 3 8 Conductor rating must comply with national state and local electrical codes Install and connect input conduc tors and grounding conductor in conduit or equivalent between wall receptacle and deenergized line disconnect device Connect grounding conductor first then line input conductors Be sure grounding conductor goes to an earth ground 5 Overcurrent Protection Select type and size using Section 3 8 Install into deenergized line disconnect device fused discon nect switch shown 6 Input Power Plug Turn Off unit Power switch and connect plug to receptacle ssb2 2 1 94 ST 156 250 A 3 8 Electrical Service Guide For 152 Ampere Models Input Voltage 230 Input Amperes At Rated Output 27 1 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 40 Min Input Conductor Size In AWG Kemil 10 Max Recommended Input Conductor Length In Feet Meters 167 51 Min Grounding Conductor Size In AWG Kemil 10 Reference 1993 National Electrical Code NEC 5 0092
56. sseur insuffi sante ou mal piss s Ne pas enrouler les cables autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour som nd fre 5 97 APA Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de conna tre les mesures prendre pour viter tout danger Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e N utiliser qu un mat riel bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixerle c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique Arr ter les convertisseurs d brancher le courant lectrique et
57. tage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output contactor does not en ergize until after tungsten electrode is touching workpiece This allows electrode to touch workpiece with out overheating sticking or getting contaminated Ref 5 156 279 4 6 Power Switch And Pilot Light 1 on ON OFF Oorr 1 Power Switch Use switch to turn unit and pilot light On and Off 2 Pilot Light OM 206 Page 17 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 5 1 Routine Maintenanc e mE 3 Months Replace Unreadable Labels 4 Replace Cracked amp 2 Replace ee Cracked Parts 14 Torch Cable 3 Months 7 I Q Tighten Weld Connections During Heavy Service Clean Monthly ST 145 666 C OM 206 Page 18 5 2 Measuring Input Capacitor Voltage Turn Off welding power source and disconnect input power Remove wrapper 1 Input Capacitor C1 Both Models 2 Input Capacitor C2 175 a Significant DC voltage can remain on capacitors after unit Models Only is Off Always check capacitors as shown to be sure they 3 Voltmeter have discharge
58. u 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 b 4 Troubleshooting section that will help you Miller is the first welding figure out what the problem is The parts list equipment manufacturer in ine US A lo 515090 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 The following terms used interchangeably throughout this manual TIG GTAW Stick SMAW 4 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State
59. welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas oylinders or any othe
60. z les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et 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 pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous e S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact phy sique ventuel avec la pi ce ou la terre Ne pas se servir de source lectrique acourant lectrique dans les zones
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