Page 2 - From Miller to You
Thank you and congratulations on choosing Miller. Now you can get thejob done and get it done right. We know you don’t have time to do it anyother 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.Li...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 4 - DECLARATION OF CONFORMITY; for European Community (CE marked) products.; Product; August 1; Massimigliano Lavarini
DECLARATION OF CONFORMITY for European Community (CE marked) products. ITW Welding Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(...
Page 5 - SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-263 706 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 7 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, ifnot avoided, will re...
Page 6 - ARC RAYS can burn eyes and skin.; BUILDUP OF GAS can injure or kill.
OM-263 706 Page 2 Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at thearc to remove we...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance
OM-263 706 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 − DEFINITIONS; Additional Safety Symbols And Definitions
OM-263 706 Page 5 SECTION 2 − DEFINITIONS 2-1. Additional Safety Symbols And Definitions . Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle ...
Page 10 - Miscellaneous Symbols And Definitions; Hz
OM-263 706 Page 6 Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 Wear hat and safety glasses. Use ear protection and button shirtcollar. Use welding helmet with correct shade of filter. Wear completebody protection. Safe38 ...
Page 11 - SECTION 3 − SPECIFICATIONS; Important Information Regarding CE Products (Sold Within The EU); IP Rating; Specifications
OM-263 706 Page 7 SECTION 3 − SPECIFICATIONS 3-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) ! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This e...
Page 12 - All Models; Duty Cycle And Overheating; A or V
OM-263 706 Page 8 3-4. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltageand amperage output capabilities of welding power source.Curves of other settings fall between curves shown. 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 DC Amperage (A) DC ...
Page 13 - SECTION 4 − INSTALLATION; Serial Number And Rating Label Location
OM-263 706 Page 9 SECTION 4 − INSTALLATION 4-1. Serial Number And Rating Label Location The serial number and rating information for the power source is located on the bottom of the machine. Use the rating labels to determine input powerrequirements and/or rated output. For future reference, write s...
Page 14 - Weld Output Terminals And Selecting Cable Sizes*; TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections
OM-263 706 Page 10 4-3. Weld Output Terminals And Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60...
Page 16 - Connecting 3-Phase Input Power
OM-263 706 Page 12 4-7. Connecting 3-Phase Input Power input2 2012−05 − 956172127_1-A = GND/PE Earth Ground L1 2 1 L2 L3 3 3 4 5 6 7 Tools Needed:
Page 17 - Connecting To 3-Phase Engine Generator w/400 Volt Output; Notes
OM-263 706 Page 13 input2 2012−05 ! Installation must meet all National andLocal Codes − have only qualified per-sons make this installation. ! Disconnect and lockout/tagout inputpower before connecting input con-ductors from unit. Follow establishedprocedures regarding the installationand removal o...
Page 18 - SECTION 5 − OPERATION
OM-263 706 Page 14 SECTION 5 − OPERATION 1 5-1. Controls (STi 270 Model Shown) 956172127_2-A 1 Voltage/Amperage Selector Switch Use switch to display welding voltage orwelding amperage. 2 Power On Pilot Light 3 High Temperature Indicator Light Light comes on if unit overheats. Weldingcan resume when...
Page 22 - Stick Start Procedure − Scratch Start Technique
OM-263 706 Page 18 5-6. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows: 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like strik-ing a match; lift electrode slightly after touch-ing work. If arc goes out electrode was liftedto high. If elect...
Page 23 - SECTION 6 − MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance; A. Welding Power Source; Blowing Out Inside Of Unit
OM-263 706 Page 19 SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance . Maintain more often during severe conditions. ! Disconnect power before maintaining. A. Welding Power Source n = Check Z = Change ~ = Clean Δ = Repair l = Replace * To be done by Factory Authorized Service Agen...
Page 24 - Troubleshooting
OM-263 706 Page 20 6-3. Troubleshooting Trouble Remedy No weld output; unit completelyinoperative. Place line disconnect switch in On position (see Section 4-7). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-7). Check for proper input power connections (see Se...
Page 25 - SECTION 7 − ELECTRICAL DIAGRAMS
OM-263 706 Page 21 SECTION 7 − ELECTRICAL DIAGRAMS 956172128_A Figure 7-1. Circuit Diagram For STi 270
Page 27 - Selecting Tungsten Electrode (; Wear Clean Gloves To Prevent Contamination Of Tungsten
OM-263 706 Page 23 SECTION 8 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2011-06 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 Tungste...
Page 28 - SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW); Positioning The Torch
OM-263 706 Page 24 SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) 9-1. Positioning The Torch Ref. ST-161 892 1 10−25 ° 10−15 ° 6 2 3 4 90 ° 4 5 3/16 in. 1/16 in. 6 5 Bottom View Of Gas Cup ! Grinding the tungsten electrodeproduces dust and flying sparkswhich can cause injury and startfires. Use local...
Page 29 - Torch Movement During Welding; Positioning Torch Tungsten For Various Weld Joints
OM-263 706 Page 25 9-2. 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 30 - SECTION 10 − STICK WELDING (SMAW) GUIDELINES
OM-263 706 Page 26 SECTION 10 − STICK WELDING (SMAW) GUIDELINES 10-1. Stick Welding Procedure stick 2013−11 − 151 593 ! Weld current starts whenelectrode touches work-piece. ! Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work cla...
Page 31 - 0-2. Electrode and Amperage Selection Chart
OM-263 706 Page 27 10-2. Electrode and Amperage Selection Chart Ref. S-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 ...
Page 33 - 0-7. Conditions That Affect Weld Bead Shape
OM-263 706 Page 29 10-7. Conditions That Affect Weld Bead Shape S-0061 Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small Angle Too Large Correct Angle Electrode Angle Arc Length Travel Speed . Weld bead shape is affectedby electrode angle, arclength, travel speed, a...
Page 37 - SECTION 11 − PARTS LIST; Circuit Card, Capacitor And Relay Board
OM-263 706 Page 33 SECTION 11 − PARTS LIST . Hardware is common and not available unless listed. 956172127_7-A 1 2 3 4 5 6 14 15 16 17 18 19 20 21 22 23 24 26 25 27 38 39 40 41 40 37 28 29 30 31 32 33 34 35 36 42 43 7 8 9 10 11 12 13 Figure 11-1. Main Assembly For STi 270 Part No. Description Item N...
Page 43 - (Equipment with a serial number preface of MD or newer)
milan_warr 2013−01 Effective January 1, 2013 (Equipment with a serial number preface of MD 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 conditionsbel...
Page 44 - Please complete and retain with your personal records.; Owner’s Record; Always provide Model Name and Serial/Style Number.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2013 Miller Electric Mfg. Co. 2013−01 I TW Welding Italy S.r.l. Via Privata Iseo, 6/E20098 San GiulianoMilanese, ItalyPhone: 39 (0) 2982901Fax: 39 (0) 298290-203email: miller@itw−welding.it Model Name Serial/Style Number Purchase Date (Date which equipment wa...
