Miller Gold Seal 160 i- User Manual

Page 2 - From Miller to You

Thank you and congratulations on choosingMiller. Now you can get the job done and get itdone right. We know you don’t have time to do itany other way. That’s why when Niels Miller first started buildingarc welders in 1929, he made sure his productsoffered long-lasting value and superior quality. Lik...

Page 3 - TABLE OF CONTENTS

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2....

Page 4 - Declaration of Conformity; Gold Seal

dec_con1_italy11/02 Declaration of Conformity Manufacturer ’s Name: ITW WELDING PRODUCTS ITALY S.r.l. Manufacturer ’s Address: Via Privata Iseo, 6/E20098 San GiulianoMilanese, Italy Declares that this product: Gold Seal R 160 i Conforms to the following Directives and Standards: Directives Electroma...

Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards

OM-189 116 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_7/02 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. T...

Page 7 - Additional Symbols For Installation, Operation, And Maintenance

OM-189 116 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 siz...

Page 9 - SECTION 2 – INSTALLATION; Specifications

OM-189 116 Page 5 SECTION 2 – INSTALLATION 2-1. Specifications Rated Welding Output Amp Range DC Maximum Open-Circuit Voltage DC IP Rating Amperes Input at Rated Load Output, 50/60 Hz, Single-Phase KVA Weight Voltage DC 230 V 240 V 160 A @ 16.4 Volts DC, 60% Duty Cycle 5 – 160 90 IP22 18 17 4 33 lb ...

Page 10 - Selecting A Location

OM-189 116 Page 6 2-3. Volt-Ampere Curve Volt-ampere curve shows mini-mum and maximum voltage andamperage output capabilities ofunit. 802 276 2-4. Selecting A Location 1 Rating Label Use rating label to determine inputpower needs. 2 Line Disconnect Device Locate unit near correct input pow-er supply...

Page 12 - Weld Output Terminals And Selecting Cable Sizes; Electrical Service Guide

OM-189 116 Page 8 2-7. Weld Output Terminals And Selecting Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Turn Off power before connecting to weld output receptacles. We...

Page 13 - Connecting Input Power

OM-189 116 Page 9 2-9. Connecting Input Power 1 Rating Label Supply correct input power. SeeSection 2-8. 2 Line Disconnect Device Check input voltage available atsite. 2 1 1 L1 L2 Y Always connect groundingconductor first. = GND/PE

Page 14 - SECTION 3 – OPERATION; Controls; SECTION 4 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance

OM-189 116 Page 10 SECTION 3 – OPERATION 3-1. Controls 1 Machine On Indicator Light 2 Welding On Indicator Light 3 Thermal Cutout WarningIndicator Light 4 Welding Current Control 5 Down Slope And Up SlopeTime Control 6 Base Current Control 7 Post-Gas time Control 8 Pulse Frequency Control 9 HF Or Li...

Page 15 - Troubleshooting

OM-189 116 Page 11 4-2. Troubleshooting Trouble Remedy No weld output; unit completely inop-erative. Be sure Power switch is On (see Section 3-1). Be sure line disconnect switch is On (see Section 2-9). Check line fuse(s) and replace if necessary (see Sections 2-9). Check for proper input power conn...

Page 16 - SECTION 5 – ELECTRICAL DIAGRAMS

OM-189 116 Page 12 SECTION 5 – ELECTRICAL DIAGRAMS GND PCB1 R S 230V S1 FM 1 PCB2 J5-J6 J7 J7 J3-J4 J8 BSI BS2 J2 10 1 PCB3 SH1 J2 J1 XL T1 J1 J2 J3 J4 J1 J2 RC1 A B D E C PCB4 J4 6 5 4 3 2 1 J4 J5 11 8 1 40 PCB6 J2 J1 12 345 778 1234 56 6 Gs RC1 PCB5 DL1 DL2 DL3 SWR1 Arc Weld T ig 4T T ig 2T Res. T...

Page 18 - Selecting Tungsten Electrode

OM-189 116 Page 14 SECTION 6 – SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw2 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 6-1. Selecting Tungste...

Page 19 - Preparing Tungsten For DC Electrode Negative (DCEN) Welding

OM-189 116 Page 15 6-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Ref. S-0161 / Ref. S-0162 1 Tungsten Electrode 2 Tapered End Grind end of tungsten on fine grit,hard abrasive wheel before weld-ing. Do not use wheel for other jobsor tungsten can become contami-nated causing lower w...

Page 20 - SECTION 7 – GUIDELINES FOR TIG WELDING (GTAW); Positioning the Torch

OM-189 116 Page 16 SECTION 7 – GUIDELINES FOR TIG WELDING (GTAW) 7-1. Positioning the Torch Ref. ST-161 892 Y Grinding the tungsten elec-trode produces dust and fly-ing sparks which can causeinjury and start fires. Use lo-cal exhaust (forced ventila-tion) at the grinder or wear anapproved respirator...

Page 21 - Torch Movement During Welding

OM-189 116 Page 17 7-2. Torch Movement During Welding ST-162 002-B Tungsten Without Filler Rod Tungsten With Filler Rod Form pool Tilt torch Move torch to front of pool. Repeat process. 75 ° 75 ° Welding direction Form pool Tilt torch Add filler metal Move torch to front of pool. Repeat process. Rem...

Page 22 - Positioning Torch Tungsten For Various Weld Joints

OM-189 116 Page 18 7-3. 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 23 - Notes

Page 24 - SECTION 8 – PARTS LIST

OM-189 116 Page 20 SECTION 8 – PARTS LIST . Hardware is common andnot available unless listed. 3 1 4 5 7 9 8 10 32 11 31 12 14 15 16 14 19 17 18 30 21 22 23 25 20 24 26 28 13 6 2 29 27 Figure 8-1. Main Assembly

Page 28 - Please complete and retain with your personal records.; Owner’s Record

PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03 Miller EuropeItalyPhone: 39 (0) 2982901 European Headquarters –United KingdomPhone: 44 (0) 1204-593493FAX: 44 (0) 1204-598066 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headqu...

Miller Gold Seal 160 i- User Manual

Table of Contents:

Summary

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