Page 2 - From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...
Page 3 - TABLE OF CONTENTS; WARNING
The following terms areused interchangeablythroughout this manual:TIG = GTAWStick = SMAW TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-206 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This ...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-206 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system isproperly sized, ...
Page 8 - EMF Information
OM-206 Page 4 1-5. EMF Information Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining mor...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-206 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Y Identifie un message...
Page 10 - LE BRUIT peut affecter l’ouïe.
OM-206 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro-voquer des ...
Page 13 - Specifications
OM-206 Page 9 SECTION 2 – SPECIFICATIONS Unless otherwise noted, the 175 model is shown throughout this manual. NOTE 2-1. Specifications Model Rated Welding Output Amperage Range Maximum Open-Circuit Voltage DC Amperes Input at Rated Load Output KVA KW Weight Overall Dimensions 152 120 A @ 25 Volts ...
Page 14 - Duty Cycle And Overheating
OM-206 Page 10 2-3. Duty Cycle And Overheating rduty1 5/95 – SB-121 591-B / SB-144 507-B / ST-157 356-B Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. Y Exceeding duty cycle candamage unit and voidwarranty. 0 15 minutes When overheated, thermostat opens,...
Page 15 - SECTION 3 – INSTALLATION; Selecting A Location
OM-206 Page 11 SECTION 3 – INSTALLATION 1 10 in (254 mm) Open SpaceOn Right Side And Rear OfUnit For Good Airflow 2 Lifting Handle Use handle to move unit. 3 Rating Label Locate unit near correct inputpower supply. Right Rear 1 3-1. Selecting A Location Ref. SA-145 666-C 2 3 1 Weld Output Cable Dete...
Page 17 - Remote 14 Socket Information; Connecting Input Power To 152 Models
OM-206 Page 13 3-6. Remote 14 Socket Information A +15 volts dc. B Contact closure to A completes +15 volts dc contactor control circuit. C Output command reference; 0 to +10 volts dc depending on setting ofAmperage Adjustment control R4. D Remote control circuit common. E Input command signal (pote...
Page 19 - SECTION 4 – OPERATION; Controls
OM-206 Page 15 SECTION 4 – OPERATION ST-152 127-A 1 Amperage Adjustment Control 2 Amperage Control Switch 3 Output (Contactor) Switch 4 Lift-Arc Switch 5 Weld Process Switch 6 Power Switch 7 Pilot Light 1 2 3 4 5 6 7 4-1. Controls 1 Output (Contactor) Switch Use switch to select way of control-ling ...
Page 20 - Amperage Controls
OM-206 Page 16 ST-159 059 / S-0769 1 Amperage Adjustment Control Use control to select weld amper-age. Amperage may be adjustedwhile welding. 2 Amperage Control Switch Use switch to select way of control-ling amperage adjustment. For front panel control, place switchin Panel position. For remote con...
Page 21 - NOTE; Power Switch And Pilot Light
OM-206 Page 17 Lift-Arc switch must be in Off position when using a High-Frequency unit with thiswelding power source, or when using the SMAW welding process. NOTE 1 Lift-Arc Switch Use switch to select Lift-Arc On orOff. With Lift-Arc On, start an arc inGTAW welding as follows: 2 GTAW Electrode 3 W...
Page 22 - SECTION 5 – MAINTENANCE & TROUBLESHOOTING; Months
OM-206 Page 18 SECTION 5 – MAINTENANCE & TROUBLESHOOTING Turn Off all power before maintaining. 3 Months OR Blow Out Or Vacuum Inside Replace Unreadable Labels 6 Months Tape Or Replace Cracked Cables ST-145 666-C Clean And Tighten Weld Connections 3 Months 14-Pin Cord Gas Hose Torch Cable Replac...
Page 23 - Measuring Input Capacitor Voltage
OM-206 Page 19 ST-153 136-B Turn Off welding power source anddisconnect input power. Remove wrapper. 1 Input Capacitor C1 (BothModels) 2 Input Capacitor C2 (175Models Only) 3 Voltmeter Check input capacitor(s). Measure the dc voltage across thepositive (+) and negative (–)terminals until voltage dro...
Page 24 - Troubleshooting
OM-206 Page 20 5-3. Troubleshooting 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...
Page 25 - Notes
Page 26 - SECTION 6 – ELECTRICAL DIAGRAMS; Figure 6-1. Circuit Diagram For 152 Model
OM-206 Page 22 SECTION 6 – ELECTRICAL DIAGRAMS SC-166 403 Figure 6-1. Circuit Diagram For 152 Model
Page 27 - Figure 6-2. Circuit Diagram For 175 Model
OM-206 Page 23 SC-170 697 Figure 6-2. Circuit Diagram For 175 Model
Page 28 - Selecting Tungsten Electrode
OM-206 Page 24 SECTION 7 – SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw 7/97 For additional information, see your distributor for a handbook on the GasTungs t en Ar c Welding (G TAW ) pr oc es s . Wear clean glov es to pr ev entcontamination of tungsten electrode. NOTE 7-1. Selecting Tungsten Ele...
Page 30 - SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW); Positioining The Torch
OM-206 Page 26 SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW) 8-1. Positioining The Torch ST-161 892 Y Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible. 1 Workpiece Make sure workpiece is cle...
Page 31 - Positioning Torch Tungsten For Various Weld Joints
OM-206 Page 27 8-3. Positioning Torch Tungsten For Various Weld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint
Page 32 - SECTION 9 – PARTS LIST
OM-206 Page 28 SECTION 9 – PARTS LIST Figure 9-1. Main Assembly (175 Model Illustrated) ST-145 668-J . Hardware is common andnot available unless listed. . *18 Is Supplied with 152 Model only *
Page 39 - (Equipment with a serial number preface of “LA” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...
Page 40 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...
