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 distributor to receive the latest fullline catalog or individual catalog sheets. To locate your nearestdistributor or service agency call 1-800-...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-316 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This g...
Page 6 - WELDING can cause fire or explosion.
OM-316 Page 2 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. ARC RAYS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes...
Page 12 - -5. Information sur les champs électromagnétiques
OM-316 Page 8 2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443 − 9353, site Web : www.aws.org). Recommended Safe Practices for the Preparation for Welding ...
Page 13 - Symbols And Definitions; Hz; Rating Label For EN/FR Machines; PHASE; KW
OM-316 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperes Single Phase Do Not Switch Under Load Input On Off Output Hz Hertz Alternating Current Electrode Positive Electrode Negative Direct Current Welding Arc V Volts Work Electrode 3-2. Manufacturer ’s Rating Labels 217 652-A / 1...
Page 14 - AC Models
OM-316 Page 10 SECTION 4 − INSTALLATION 4-1. Specifications AC/DC Models Mode Rated Welding Output Amperage Range Maximum Open- Circuit Amperes Input at Rated Load Output 50 Or 60 Hz, Single-Phase Weight Mode Output Range Circuit Voltage 115 V 220 V 230 V 400 V 460 V Weight AC 225 A @ 25 Volts AC, 2...
Page 17 - B. For 220 Volt Model
OM-316 Page 13 B. For AC Models 193 508 / 193 513 / 193 511 The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. A. For 115/230 And 230 Volt Models (225 Amperes) B. For 220 Volt Model (300 Amperes) C. ...
Page 19 - -5. Installing Electrode Holder And Work Clamp; NOTE
OM-316 Page 15 4-5. Installing Electrode Holder And Work Clamp 802 251 / 802 105-C Y Turn Off unit and disconnect input power before installing electrode holder or work clamp. Removing Barrel From Elec- trode Holder 1 Electrode Holder 2 Barrel 3 Access Hole 4 Set Screw Loosen set screw through acces...
Page 21 - Models From 115 Volts
OM-316 Page 17 4-8. Internal Connections For Operating 115/230 Volts, 225 Amperes AC And AC/DC Models From 115 Volts Follow applicable electrical codes and have a competent electrician make internalconnections. Note the input amperes as stated in Section 4-7. NOTE Y Turn Off unit and disconnect inpu...
Page 22 - Amperes AC Models From 230 Volts
OM-316 Page 18 4-9. Internal Connections For Operating 230/400 Volts, 300/200 Amperes AC/DC Or 300 Amperes AC Models From 230 Volts Follow applicable electrical codes and have a competent electrician make internalconnections. Note the input amperes as stated in Section 4-7. NOTE Ref. 802 247-D 1 2 3...
Page 23 - Or
OM-316 Page 19 4-10. Connecting Input Power Ref. 802 246 For Models Supplied With Plug Y Disconnect and lockout/tag- out input power before instal- ling receptacle. Y Have only qualified persons make this installation. See rating label in Section 4-4, and be sure to supply correct in- put power. 1 P...
Page 25 - B. Controls For AC Models
OM-316 Page 21 B. Controls For AC Models Ref. 218 237-A / 802 105-C 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch Use mode switch to select ac low range or high range output. 1 3 2
Page 26 - Months
OM-316 Page 22 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Repair Or Replace Cracked Cables 6 Months 12 Months Blow Out Or Vacuum Inside, During Heavy Service, Clean Monthly OR Lubricate Shunt Block ...
Page 27 - -3. Reinstalling Amperage Adjustment Indicator
OM-316 Page 23 6-3. Reinstalling Amperage Adjustment Indicator Ref. 218 237-A / 802 248-C Y Turn Off welding power source and disconnect input power. 1 Wrapper Remove wrapper from unit.2 Crank Handle 3 Shunt Shaft 4 Transformer And Shunt (Located Inside Unit) Insert crank handle onto shunt shaft pro...
Page 35 - -2. Electrode And Amperage Selection Chart
OM-316 Page 31 8-2. Electrode And Amperage Selection Chart Ref. 087 985-A 3/32 1/8 5/323/167/32 1/4 1/165/643/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/163/32 1/8 5/32 6010 & 6011 6013 7014 7018 7024 Ni-Cl 308L 50 100 150...
Page 37 - -6. Conditions That Affect Weld Bead Shape
OM-316 Page 33 8-5. Weld Bead Characteristics Ref. S-0052-B 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1/8 in (3.2 mm) thickness in meta...
Page 39 - B. Welding Troubleshooting
OM-316 Page 35 8-9. Lap Joints S-0063 / S-0064 1 Electrode 2 Single-Layer Fillet Weld Move electrode in circular motion.3 Multi-Layer Fillet Weld Weld a second layer when a larger fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength. 30 ° Or Le...
Page 44 - Notes
Page 45 - Pros weld and cut
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules atthe beginningof this manual.
Page 47 - (Equipment with a serial number preface of “LE” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 6/04 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 quest...
Page 48 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2004 Miller Electric Mfg. Co. 1/04 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 & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Europe...