Page 2 - To locate your nearest; Thank you; 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 specification sheets. To locate your nearest distributor or service agency call...
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-225 389 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adj...
Page 6 - WELDING can cause fire or explosion.
OM-225 389 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 an approved welding helmet fitted with a proper shade of fil- ter lenses to pro...
Page 7 - ARC WELDING can cause interference.
OM-225 389 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 near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly s...
Page 9 - Symboles utilisés; Dangers relatifs au soudage à l’arc; UNE DÉCHARGE ÉLECTRIQUE peut
OM-225 389 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comport...
Page 11 - LE RAYONNEMENT HAUTE; Proposition californienne 65 Avertissements
OM-225 389 Page 7 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammable...
Page 12 - Principales normes de sécurité; Information EMF
OM-225 389 Page 8 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of...
Page 16 - -8. Weld Output Terminals And Selecting Cable Sizes
OM-225 389 Page 12 3-7. AC Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. ssb1.1 10/91 − 226 799-A AMPS 0 10 0 50 100 150 200 20 30 40 50 60 70 AC TIG Max AC Stic...
Page 17 - Socket Information
OM-225 389 Page 13 3-9. Remote 14 Receptacle Socket* Socket Information A 15 volts DC. B Contact closure to A completes 15 volts DC contactor control circuit. C Command reference; 0 to +10 volts DC output to remote control. A J B K I A D Remote control circuit common. B K I C L N H D M G A E 0 to +1...
Page 20 - Actual input voltage cannot exceed; NOTE
OM-225 389 Page 16 3-13. Typical Stick Connections Y Turn off power before mak- ing connections. 1 Electrode Holder 2 Work Clamp Connect electrode holder and work clamp to receptacles as shown. 1 2 3-14. Electrical Service Guide All values calculated at 40% duty cycle. NOTE Actual input voltage cann...
Page 21 - A. Placing Jumper Links
OM-225 389 Page 17 3-15. Connecting Input Power In 208 − 230 Volt Models Tools Needed: L1 L2 804 234-B / Ref. 803 766-B 1 =GND/PE Earth Ground Y Installation must meet all National and Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power b...
Page 22 - B. Connecting Input Power In 460/575 Volt Models
OM-225 389 Page 18 B. Connecting Input Power In 460/575 Volt Models Tools Needed: 804 470-A Y Installation must meet all National and Local Codes − have only qualified per- sons make this installation. Y Disconnect and lockout/tagout input power before connecting input con- ductors from unit. Y Make...
Page 27 - -7. Factory Parameter Defaults And Range And Resolution; Parameter
OM-225 389 Page 23 4-7. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution PROCESS TIG HF TIG HF, STICK A MAIN / PEAK AC DC 150 A 150 A 5 − 200 Amps 5 − 200 Amps PULSER PPS PEAK t BKGND A Off 10 PPS 50% 50% ON / OFF 0.1 − 15 PPS 20 − 80 Percent 5 − 95 Percent ...
Page 29 - -9. Selecting Syncro Start Characteristics; DCEN
OM-225 389 Page 25 4-9. Selecting Syncro Start Characteristics 1 Power Switch 2 Main Amps Control 3 Volt And Ammeters 4 Process Selector Switch To change TIG HF Syncro starting char- acteristics, turn Off power, place Output Selector switch in desired position, DCEN, DCEP or AC. Each position has th...
Page 30 - PK T
OM-225 389 Page 26 1 Power Switch 2 Pulse Control Push and hold Pulser button and turn on power. Hold button for approxi- mately 7 seconds.3 Encoder Control 4 Volt And Ammeter Press Pulse button to cycle parame- ters (see Section 4-7 for parameter ranges). PPS (Pulses Per Second or Pulse Frequency) ...
Page 35 - Trouble
OM-225 389 Page 31 5-4. Troubleshooting NOTE: The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit. There are no user serviceable parts inside unit. Refer to Section 5-3 for any Help ( HLP ) me...
Page 40 - Wear Clean gloves To Prevent Contamination Of Tungsten
OM-225 389 Page 36 SECTION 8 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING ac/dc_gtaw 2/2000 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 Tungsten ) Amperage Rang...
Page 41 - -2. Preparing Tungsten Electrode For Welding; B. Preparing Tungsten For Conventional AC Welding
OM-225 389 Page 37 8-2. Preparing Tungsten Electrode For Welding Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor- mation. Conside...
Page 42 - SECTION 9
OM-225 389 Page 38 SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) 9-1. Positioning The Torch Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. . For additional information, seeyour dis...
Page 44 - -3. Positioning Torch Tungsten For Various Weld Joints
OM-225 389 Page 40 9-3. Positioning Torch Tungsten For Various Weld Joints ST-162 003 / S-0792 75 ° 70 ° 90 ° 20 ° 20 ° 10 ° 15 ° 75 ° 20-40 ° 30 ° 15 ° 75 ° 90 ° 15 ° Butt Weld And Stringer Bead “T” Joint Lap Joint Corner Joint
Page 48 - 0-8. Conditions That Affect Weld Bead Shape; thickness of base metal.; multiple stringer beads work better.
OM-225 389 Page 44 10-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRAVEL SPEED Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Sma...
Page 50 - Porosity; Excessive Spatter
OM-225 389 Page 46 10-13. Weld Test S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in 1/4 in 3 21 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 10-14. Troubleshooting − Porosity Porosity − small cavities or holes resulti...
Page 53 - Notes
Page 54 - PARTS LIST
OM-225 389 Page 50 SECTION 11 − PARTS LIST 804 237-D . Hardware is common andnot available unless listed. 1 2 57 56 55 53 54 4 3 5 6 7 8 9 10 14 13 1211 15 17 18 57 21 22 23 20 19 27 26 28 29 30 31 32 33 34 57 25 35 37 38 25 36 16 24 39 40 41 42 43 47 46 45 44 48 49 51 50 52 58 Figure 11-1. Main Ass...
Page 59 - Figure 11-4. Factory Optional Running Gear
OM-225 389 Page 55 804 414-B . Hardware is common andnot available unless listed. Optional 6 7 8 1 2 5 6 7 8 9 10 11 4 3 12 Figure 11-4. Factory Optional Running Gear Description Part No. Dia. Mkgs. Item No. Figure 11-4. Factory Optional Running Gear (Figure 11-1 Item 57) Quantity 1 +222 775 COVER, ...
Page 63 - (Equipment with a serial number preface of “LF” or newer)
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 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 64 - Please complete and retain with your personal records.; Contact a DISTRIBUTOR or SERVICE AGENCY near you.; For Service
PRINTED IN USA © 2005 Miller Electric Mfg. Co. 1/05 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...
