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 - SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards
OM-611 Page 1 Return To Table Of Contents SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 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”; ...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; California Proposition 65 Warnings
OM-611 Page 3 Return To Table Of Contents 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 supp...
Page 8 - Principal Safety Standards
OM-611 Page 4 Return To Table Of Contents 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126(phone: 305-443-9353, website: www.aws.org). Recommended Safe Practices for the Preparatio...
Page 9 - SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT; Signification des symboles; Dangers relatifs au soudage à l’arc
OM-611 Page 5 Revenez à la table des matières SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. »Cette procédure présente des risques identifiés par lessymboles adjacents aux directives. Y Id...
Page 12 - Principales normes de sécurité
OM-611 Page 8 Revenez à la table des matières 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 ...
Page 13 - SECTION 3 − INSTALLATION; Specifications
OM-611 Page 9 Return To Table Of Contents SECTION 3 − INSTALLATION 3-1. Specifications Welding Circuit Rat- Input Power Cord With Type Of Input Power Dimensions Weight Circuit Rat- ing Cord With Plug 115 Volts 230 Volts Height Width Length 115 Volts 230 Volts 250 Amperes At 60% Duty Cycle 10 ft (3 m...
Page 14 - Installing Gas Supply
OM-611 Page 10 Return To Table Of Contents Obtain gas cylinder and chain torunning gear, wall, or other station-ary support so cylinder cannot falland break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve,and open valve slightly. Gas flowblows dust and dirt from valve.Close valv...
Page 15 - NOTE; Power Source Plug Information And Connections
OM-611 Page 11 Return To Table Of Contents The supplied cord with plugs is for use with CC or CC/CV welding power sourceshaving the proper, matching 14-pin receptacle. Do not use cordset on machineswithout the 14-pin receptacle. NOTE 159 645-A / Ref. S-0004-A / S-0283-A Y Turn Off HF Unit and weldin...
Page 16 - Operator Control Receptacle Information And Connections
OM-611 Page 12 Return To Table Of Contents sb7.1 5/94 − Ref. 098 957-D / Ref. S-0004-A / S-0750 / Ref. 141 127-B 1 Operator Control ReceptacleRC1 (See Section 3-6) 2 Keyway 3 Plug 4 Threaded Collar To connect to receptacle, alignkeyway, insert plug, and tightenthreaded collar. 3 4 OR A J B K I C L N...
Page 17 - CAUTION; Connecting To Weld Output Terminals
OM-611 Page 13 Return To Table Of Contents Y Turn Off HF Unit and weldingpower source, and discon-nect input power beforemaking connections. Stopengine on welding genera-tors. Y Not connecting work cablesto HF Unit will damage powersource. Always connectwork cables to Work Input/Output terminal. 1 E...
Page 18 - Connecting Input Power
OM-611 Page 14 Return To Table Of Contents Ref. 159 606-B / Ref. 149 354-A Y Read and follow entire Sec-tion 8 about HF equipment be-fore installing unit. Y Direct Current (DC) will dam-age HF Unit. Connect unitonly to Alternating Current(AC) supply. Do not cutgrounding terminal off plug. 1 Grounded...
Page 19 - SECTION 4 − OPERATION; Controls; High Frequency Switch
OM-611 Page 15 Return To Table Of Contents SECTION 4 − OPERATION Ref. 098 956-D 1 Power Switch 2 Pilot Light 3 High Frequency SelectorSwitch 4 High Frequency Switch 5 High Frequency IntensityControl 4 5 1 2 3 4-1. Controls Ref. 139 573 1 High Frequency Switch Start − provides HF for arc startingonly...
Page 20 - High Frequency Intensity Control
OM-611 Page 16 Return To Table Of Contents 1 High Frequency IntensityControl Use control to change amount ofHF energy used to start and/ormaintain the arc. Set as low aspractical to prevent interfering withelectronic equipment. 1 4-4. High Frequency Intensity Control 1 Power Switch Use switch to tur...
Page 21 - SECTION 5 − MAINTENANCE & TROUBLESHOOTING; Months
OM-611 Page 17 Return To Table Of Contents SECTION 5 − MAINTENANCE & TROUBLESHOOTING Disconnect all power before maintaining. 3 Months OR Blow Out Or Vacuum Inside Clean And Tighten Weld Terminals Replace Unreadable Labels 6 Months 14-Pin Cord Gas Hose Torch Cable Replace Cracked Parts Adjust Sp...
Page 22 - Adjusting Spark Gaps
OM-611 Page 18 Return To Table Of Contents Ref. 098 956-G Turn Off unit and welding powersource and disconnect input power. Loosen screw on spark gap accessdoor and open. 1 Tungsten End Of Point Do not clean or dress tungsten.Replace point if tungsten enddisappears. 2 Spark Gap Normal spark gap is 0...
Page 23 - Troubleshooting
OM-611 Page 19 Return To Table Of Contents 5-3. Troubleshooting Trouble Remedy Unit completely inoperative; Pilot lightOff. Secure input power cord plug in receptacle (see Section 3-8). Place Power switch in the On position (see Section 4-5). Lack of high-frequency; difficulty in es-tablishing an ar...
Page 24 - SECTION 6 − ELECTRICAL DIAGRAMS
OM-611 Page 20 Return To Table Of Contents SECTION 6 − ELECTRICAL DIAGRAMS 130 555-D Figure 6-1. Circuit Diagram For 115 Volts Model
Page 26 - SECTION 7 − HIGH FREQUENCY; Welding Processes Requiring High Frequency
OM-611 Page 22 Return To Table Of Contents SECTION 7 − HIGH FREQUENCY 7-1. Welding Processes Requiring High Frequency high_freq 12/96 − S-0693 1 High-Frequency Voltage TIG − helps arc jump air gapbetween torch and workpiece and/or stabilize the arc. 1 TIG Work 7-2. Incorrect Installation 50 ft (15 m...
Page 27 - Correct Installation
OM-611 Page 23 Return To Table Of Contents 7-3. Correct Installation 1 High-Frequency Source (weldingpower source with built-in HF orseparate HF unit) Ground metal machine case, work outputterminal, line disconnect device, inputsupply, and worktable.2 Center Point of Welding Zone Midpoint between hi...
Page 28 - SECTION 8 − SELECTING AND PREPARING TUNGSTEN; Selecting Tungsten Electrode (
OM-611 Page 24 Return To Table Of Contents SECTION 8 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING ac/dc_gtaw 2/2004 Y Whenever possible and practical, use DC weld output instead of AC weld output. 8-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of ...
Page 29 - Preparing Tungsten Electrode For Welding; SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW); Positioning The Torch
OM-611 Page 25 Return To Table Of Contents 8-2. Preparing Tungsten Electrode For Welding Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Uselocal exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety...
Page 30 - Torch Movement During Welding; Positioning Torch Tungsten For Various Weld Joints
OM-611 Page 26 Return To Table Of Contents 9-2. Torch Movement During Welding 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...
Page 31 - Notes
Page 32 - SECTION 10 − PARTS LIST
OM-611 Page 28 Return To Table Of Contents SECTION 10 − PARTS LIST Figure 10-1. Complete Assembly (Part 1 of 2) (115V Model) 098 955-L Part 1 of 2 . Hardware is common andnot available unless listed. 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 19 20 21 22 23 18 24 25 26 27 28 29 30 31 32 12 33 34 35 14 36
Page 39 - (Equipment with a serial number preface of “LC” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 8/03 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 2004 Miller Electric Mfg. Co. 1/04 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...
