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 - Declaration of Conformity For; NOTE; Syncrowave
dec_con1_11/02 Declaration of Conformity For European Community (CE) Products This information is provided for units with CE certification (see rating label on unit.) NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W. Spencer StreetAppleton, WI 54914 USA Declares th...
Page 6 - Notes
Page 7 - Symbol Usage; Arc Welding Hazards
OM-356 Page 1 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”; not safety related. This gro...
Page 9 - Additional Symbols For Installation, Operation, And Maintenance; California Proposition 65 Warnings
OM-356 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 sized, ...
Page 11 - Signification des symboles; Dangers relatifs au soudage à l’arc
OM-356 Page 5 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 Identifie un message de sécurité p...
Page 15 - SECTION 3 − DEFINITIONS; Warning Label Definitions
OM-356 Page 9 SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions Warning! Watch Out! There are possiblehazards as shown by the symbols. 1 Electric shock from welding electrodeor wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Donot wear wet or damaged glov...
Page 17 - Manufacturer ’s Rating Label For CE Products
OM-356 Page 11 3-4. Manufacturer ’s Rating Label For CE Products
Page 18 - Symbols And Definitions; IP
OM-356 Page 12 3-5. Symbols And Definitions Some symbols are found only on CE products. NOTE A Amperes Panel−Local Gas Tungsten Arc Welding (GTAW) Shielded Metal Arc Welding (SMAW) V Volts Do Not Switch While Welding Arc Force (DIG) Spot Timer Output Circuit Breaker Remote Temperature Protective Ear...
Page 19 - SECTION 4 − INSTALLATION; Selecting A Location
OM-356 Page 13 SECTION 4 − INSTALLATION OR Location And Airflow Y Falling Unit Can CauseInjury. S Use lifting eye to lift unit only,NOT running gear, gascylinders, or any otheraccessories. S Use equipment of adequatecapacity to lift and supportunit. S If using lift forks to move unit,be sure forks a...
Page 21 - Duty Cycle And Overheating
OM-356 Page 15 6 Minutes Welding 4 Minutes Resting 4 Minutes Welding 6 Minutes Resting 4-4. Duty Cycle And Overheating Duty Cycle is the percentage of 10minutes that the unit can weld atrated load without overheating. If unit overheats, output stops, frontpanel voltmeter/ammeter displaysa HLP3 or HL...
Page 23 - Shielding Gas Connections And 115 Volts AC Duplex Receptacle
OM-356 Page 17 4-8. Shielding Gas Connections And 115 Volts AC Duplex Receptacle Ref. ST-801 972-C / Ref. ST-801 973 / Ref. ST-157 858 Y Turn Off power before mak-ing connections. 1 Gas Valve In Fitting Located on rear of unit. 2 Gas Valve Out Fitting Fittings have 5/8-18 right-handthreads. 3 Cylind...
Page 24 - Electrical Service Guide
OM-356 Page 18 4-9. Electrical Service Guide All values calculated at 60% duty cycle. NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range, damage to unitmay occur. NOTE 50/60 Hertz Models Without Pow...
Page 27 - SECTION 5 − OPERATION; Controls
OM-356 Page 21 SECTION 5 − OPERATION 5-1. Controls A. For 200/230/460 Volts And Non CE Units Ref. ST-183 200-A / Ref. ST-183 260-A / Ref. ST-801 972-C . Top row of lights in upper left corner areOn for SMAW. Bottom row are On forGTAW. 1 Process Control See Section 5-3. 2 Current Control See Section ...
Page 29 - Process Control
OM-356 Page 23 5-2. Output Selector Switch Ref. ST-191 372 1 Output Selector Switch Y Do not use AC output indamp areas, if movement isconfined, or if there is dan-ger of falling. Use AC outputONLY if required for thewelding process, and thenuse a remote control. Y Do not change position ofswitch wh...
Page 30 - Output Control
OM-356 Page 24 5-4. Current Control 1 Current Control Use control to select front panel orremote current control. For front panel current control,press button to toggle LED to Panelposition. For remote current control, pressbutton to toggle LED to Remote 14position (see Section 4-7). NOTE: Lit LED i...
Page 31 - Start Mode
OM-356 Page 25 5-6. Start Mode 1 Start Mode For SMAW welding, press button to toggleLED to Off position. For GTAW welding, use control to select Offfor no HF, Lift-Arc t , HF for arc starting only, or continuous HF. Application: When Off is selected, use the scratch meth-od to start an arc for both ...
Page 32 - Meters
OM-356 Page 26 5-7. Meters 1 Voltmeter Voltmeter displays average voltage(to the nearest 0.1 V) at the weldoutput terminals. 2 Ammeter Use meter to preset amperage. Me-ter displays average weld amper-age output of unit to nearest am-pere when welding. 1 2 5-8. Amperage Adjustment Control 1 Amperage ...
Page 38 - -16. Crater Time Control And Final Current Control
OM-356 Page 32 5-16. Crater Time Control And Final Current Control 1 Sequence Selection Switch Place switch in Crater position. 2 Crater Time Control Use control to reduce currentover a set period of time (0−15seconds) at the end of the weldcycle when NOT using a remotecurrent control. 3 Final Curre...
Page 42 - SECTION 6 − MAINTENANCE & TROUBLESHOOTING; Routine Maintenance; Months
OM-356 Page 36 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Clean And Tighten Weld Terminals Repair Or Replace Cracked Weld Cables Adjust Spark Gaps Replace Cracked Parts 14-Pin Cord Gas Hose Torch Ca...
Page 43 - Adjusting Spark Gaps
OM-356 Page 37 6-3. Adjusting Spark Gaps Ref. ST-801 972-C Y Turn off welding powersource and disconnect andlockout/tagout input powerbefore adjusting spark gaps. Open access door. 1 Tungsten End Of Point Replace point if tungsten end dis-appears; do not clean or dresstungsten. 2 Spark Gap Normal sp...
Page 44 - Voltmeter/Ammeter Help Displays
OM-356 Page 38 6-4. Voltmeter/Ammeter Help Displays . All directions are in reference to the frontof the unit. All circuitry referred to is lo-cated inside the unit. 0 Help 0 Display Indicates a short in the thermal protection cir-cuitry located on the transformer of the unit.If this display is show...
Page 45 - Troubleshooting
OM-356 Page 39 6-5. Troubleshooting NOTE: The remedies listed below are recommendations only. If these remedies do not fixthe trouble with your unit, have a Factory Authorized Service Agent check unit.There are not user serviceable parts inside unit. Refer to Section 6-4 for any Help (HLP) message d...
Page 46 - Pros weld and cut
OM-356 Page 40 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules atthe beginningof this manual.
Page 47 - SECTION 7 − ELECTRICAL DIAGRAM
OM-356 Page 41 SECTION 7 − ELECTRICAL DIAGRAM SC-187 950-H Figure 7-1. Circuit Diagram
Page 48 - SECTION 8 − HIGH FREQUENCY; Welding Processes Requiring High Frequency
OM-356 Page 42 SECTION 8 − HIGH FREQUENCY 8-1. 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 8-2. Incorrect Installation 50 ft (15 m) S-0694 Sources of Direct H...
Page 49 - Correct Installation
OM-356 Page 43 8-3. 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 high-frequency sourceand weldi...
Page 50 - SECTION 9 − PARTS LIST
OM-356 Page 44 SECTION 9 − PARTS LIST . Hardware is common andnot available unless listed. Figure 9-1. Main Assembly
Page 55 - (Equipment with a serial number preface of “LE” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 6/04 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 56 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2004 Miller Electric Mfg. Co. 1/03 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...
