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DIVERSION 165 - Rapid Welding and Industrial Supplies Ltd

1. 5 2 1 JVWITDOIGS USES e span rcv rd ace Bab free a re etse dnce o ee Dalee aad eh RERUM een en 5 2 2 Dangers relatifs au soudage l arc 1 cee net e 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de S curit s Gots de die eua tale cds bets Gant ow DA Ae 9 2 6 Information EMF sers renia soc Rex whale coeds Gees Weal dS BE RE bee en Si ER 9 SECTIONS SPECIFICATIONS eco A pue REX Oa Kr ERU FCR UR ROS EROS CRUCE ate 11 93st dneladecwithz Yol UM ua o potters Gene Satie a Geom PURUS qo rase Suite anre o aa Ox eos 11 3 21 O PECCO var A Gita te NAS hated et abide amaras ener 11 9 9 RAIN EdDelS xpi er eed tuat ares ALEA gute ipae eue Rec EM Ed 11 9 4 JDimerisionsnd VVelolils oso ede aet hanes dead ees ous ae doa eens ee nen 12 3 D ly Oycle ENEE sei ed a ete ek AS RT etd ER as ce ra IN ts A AA da eta hla uta 12 SECTION 4 INSTALLATION osc ox de esc a ce eee eee tee ere Mh eon ee tero Roa Qe Cn a oru Oe 13 4l SCIECING A LOCAUON 2263 0 Re br had Ae ee ee Ak ERE ORS EES SP aR OSE REAR OTERO eae 13 4 2 Remote Receptacle For Optional Foot Control 13 4 3 Shielding Gas Connections r isesi sooo eee CER eRe Ee ee REE RAS ES CIEN REESE 14 4 4 Electrical Service Guide d
2. Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit CHASSIS PCe RC3 PLG23 RC4 PLG24 RCS PLG2S UL C TORCH C WORK SECONDARY THERMISTOR 232 891 E it Diagram Ircul Figure 7 1 C SECTION 8 HIGH FREQUENCY 8 1 Welding Processes Requiring High Frequency 1 High Frequency Voltage TIG helps arc jump air gap between torch and workpiece and or stabilize the arc high freq 7 05 S 0693 8 2 Incorrect Installation AY A E v APG _ 9 a E757 NY LA TER a inc i Sources of Direct High Frequency Sources of Conduction of High Sources of Reradiation of High Radiation Frequency Frequency 1 High Frequency Source welding 7 Input Power Cable 10 Ungrounded Metal Objects power ES alt built in HF or 8 Line Disconnect Device 11 Lighting o Tee unt 9 Input Supply Wiring 12 Wiring 3 Torch 13 Water Pipes and Fixtures 4 Work Clamp 14 External Phone and Power Lines 5 Workpiece 6 Work Table OM 232 895 Page 21 8 3 Correct Installation Ground all metal ob jects and all wiring in welding zone using 12 AWG wire Ne Nonmetal Building 1 High Frequency Source welding power source with built in HF or separate HF unit Ground metal machine case work output terminal line disconnect device input supply an
3. e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment a AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes
4. Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can injure e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away STATIC ESD can damage PC boards J e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 2 em MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire 4 3 K MOVING PARTS can injure e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place d D e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read th
5. e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and
6. OM 232895G 2009 08 Miller ae TIG GTAW Welding Description cord 230 Volt Arc Welding Power Source DIVERSION 165 230 Volt 60 Hz TIG Only File TIG GTAW Rd OWNER S MANUAL Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other 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 Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir Y E BL El Her This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They boleu EE jue ere ex e f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus Ios and easy With Miller you can count on years Ni 00012000 of reliable service with proper maintenance And if for
7. souder DC fil tension constante est re command e En outre ne pas travailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud
8. Guidelines The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage For example if tungsten is 1 16 in diameter gas cup should be a minimum of 3 16 in diame ter Tungsten extension is the distance the tungsten extends out gas cup of torch The tungsten extension should be no greater than the inside diameter of the gas cup Arc length is the distance from the tungsten to the workpiece Ref 161 892 10 2 Torch Movement During Welding Tungsten Without Filler Rod Welding direction 75 POTE ODL LMG MSIL IEA VOLO A AED LL PETITE AE SIA Form pool Tilt torch Move torch to front of pool Repeat process Tungsten With Filler Rod Welding direction 75 15 2 ns d 97 47 27 4 P LE a RICO ESTAR A B COU 7 E L p LL Le Form pool Tilt torch Add filler metal _y LLLLLI TA Remove rod Move torch to front of pool Repeat process 10 3 Positioning Torch Tungsten For Various Weld Joints T Joint 20 iS 750 15 CE 10 Corner Joint i ANM IN z gt OM 232 895 Page 25 Butt Weld And Stringer Bead Lap Joint 162 003 SECTION 11 PARTS LIST 805 115 B Figure 11 1 Main Assembly OM 232 895 Page 26 Item Dia Part No Mkgs No Description Quantity Figure 11 1 Main Assembly CR TERRE 232 868 Wrapper ir epar iex Nba tole air ep eie SR c etel 1 a gocce 230 366
9. Label Warning General Precautionary Static 1 tu n 232 915 Cord Set 250v 6 50p 12ga 3 C 7ft Spt 3 Jkt 1 sce cm 188 048 Hose Norn Brd No 1 X 250 Id X 18 000 1 5 GS1 216607 Valve 24vdc 2way Custom Port 1 8 Orf W Frict 1 RE SR e 111 443 Bushing Strain Relief 240 510 Id X 875 Mtg Hole 1 7 CB1 233184 Supplementary Protector Man Reset 1p 35a 250vac 1 E car bee 292 009 x Pane l REA et a oun it te A aan as hae en Co re ee ef Dass A 1 tas OF p 137 761 Nut 750 NPT 1 31 Hex 27 H Nyl Blk 1 vada ena echt 232 940 Ftg Hose Brs Barbed M 3 16 Tbg X 5 8 18 Thrd 1 es deat a ee an Bee 232 901 Handle Carrying 2 Rs N 232 939 Hose Sae 187id X 4100d X 12 Ft 1 T sieseesit 235 424 Regulator Flowmeter 10 50 CFH Argon CO2 1 A us El gona 297414 AMQUCION INDUL concen lucie da eau em Eee OE Ce ai e oe acide tuyo 1 AN 232 922 Windtunnel Assembly see Figure 11 2 1 NE AAA 083 147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 4 17 PC1 230058 Circuit Card Assy Control amp Interface 1 18 FM1 232923 Fan Muffin 24vdc
10. Leds Cp Flat 1t 2 1 00 T2 232909 Inductor Arc Starter Output 150 Amp 1 37 POS 212 890 Circuit Card Assy Arc Starter 1 iO Abos Sek L2 208066 Inductor Toroid 5 Amp 180 Uh 12 Leads W Quick Con 1 No NCC 210 323 Insulator Washer Inductor 1 1 AUS A gt 185 835 Label Warning Electric Shock Exploding Parts 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 232 895 Page 27 Hardware is common and not available unless listed 805 135 B Figure 11 2 Windtunnel Assembly Item Dia Part No Mkgs No Description Quantity 232 922 Figure 11 2 Windtunnel Assembly Figure 11 1 Item 15 1 PC2 230 144 Circuit Card Assy Commutator Control 1 rA 242 084 Bushing Snap In NYL i242 ear iem dee ho a dee ene cede de Re ea 6 wo 2 190 512 2x olan Ol atrial edt Eo tried 4 cub edere 1232 9007 x Patel MIODIADB siad etd duce ieee Ha one paci d oo ero e Ee diets dd 1 5 T1 237 413 XFMR Main Includes tir AA cet eR 1 6 RT3 207 890
11. P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux let l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 t l phone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 t l hone 1 800 232 4636 site internet www cdc gov NIOSH 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 232 895 Page 9 OM 232 895 Page 10 SECTION 3 SPECIFICATIONS 3 1 Included with Your Unit Welding Power Source 5 ft 1 5 m Primary Cord Wi
12. PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state F F gt In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2009 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal S
13. Thermistor NTC 10K Ohm 25 Deg C 27 50 In Lead 1 r A 232 917 Heat Sink Secondary Assy See Figure 11 3 1 sd sal 2 297418 s MAUGO OUUTE pisa E Ge aa 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 232 895 Page 28 Hardware is common and not available unless listed 805 123 A Figure 11 3 Heat Sink Secondary Assembly Item Dia Part NO Mkgs No Description Quantity 232 917 Figure 11 3 Heat Sink Secondary Assembly Figure 11 2 Item 7 be d daas 232 869 Heat Sink Secondary 0 teense 1 2 D9 D12 231 396 Diode Ultra Fast Recovery 90 A 600 V Dual SOT 227 2 3 Q2 3 4 5 231 393 Transistor IGBT 100 A 600 V SOT 227 4 4 RT2 213 353 Thermistor NTC 30K Ohm 25 Deg C8 In Lead 1 BE o MEET 212 038 Screw M4 7 x 8 5 Pan HD PHL STL PLD Sems Split Fl 15 6 SR1 199 952 Diode Power Module 50 Amp 600 V 1 PH Fast Recovery 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required wh
14. e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s a deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 232 895 Page 5 Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup e e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces LES PIECES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains
15. tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de ca bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong ni
16. 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard 287 1 from American National Standards Institute 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 232 895 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or
17. 3 2 400 EJ E EN a RENE 5 A B E O EA NEN p ES AY DOM EU AA PR Er E ME li AN 10 Duty Cycle 100 20 Duty Cycle at 150 A AC DC 2 Minutes Welding 8 Minutes Resting 232 918 B OM 232 895 Page 12 SECTION 4 INSTALLATION 4 1 Selecting A Location 1 Handles Use Handles to lift welder get help if necessary 2 Cart Movement Place welder on cart to move unit 3 Line Disconnect Device Locate unit near correct input pow er supply Position unit so air can circulate For information about sources of high frequency see Section 8 A For carts and caster kits see back Do not move or operate unit where it could tip of book or contact your distributor Location And Airflow Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 18 in 460 mm 18 in 460 mm 18 in 460 mm 18 in 460 mm 4 2 Remote Receptacle For Optional Foot Control NOTICE Use this receptacle to connect the dedicated optional foot control only Connecting other types of equipment to this receptacle may damage your machine gt Socket Socket Information 1 Command reference 10 volts DC output to remote control 2 0 to 10 volts DC input command signal from remote control 3 Remote control circuit common 805 113 A A 4 15 volts DC 6 Contact closure to 4 completes 15 volts DC contactor control circ
18. 4500 Rpm 240 Cfm 4 125 Mtg Holes 1 TEL PDC P 238 960 x PIENUM A aont ict acute ics etd uera Ga oak eee n ene te a 1 Mu pP 232 903 DASS Sus RS nd ad dace knee wea aie Grates t dia a 1 A ER ea 239 388 Bumper RBR 875 OD X 188 ID X 39 High Recessed 4 DC NICE 239 200 Cable Assy RJ45 cedere ome Eee eb e eant d dada 1 co MO 92 134847 Switch Tgl Spdt 15a 125vac On none on Spd Term Blk 1 or PEE 231 238 Nut 468 32 56 Hex 09 H Brs Blk Use w Switches 2 om 217 839 Nut Nylon Strain RIf Pg13 5 250thk 1 0620d 1 iD adn ate epic 232 908 Work Cable W Clamp 12 1 mcm 235 392 Torch Tig 150a 12ft Air Cooled 1 NIE 233 187 Strain Relief Cable 250 Cable Dia 5x 450 D Hole 1 ORE esa deity EET 207 079 Knob Pointer 1 125 Dia 1 1 dud A 178355 Nut 375 32 54 Hex 25 H Nyl Flange 62 D 1 in accedo BOW ee Malan 232 896 Nameplate Miller Diversion 165 0 0 ccc ees 1 De WAH a TS 298 954 s A ete koe oce eoe tede et eon eed ol aas terii de ee Ot OE x 1 Mu cS 292320 INUE INVION THO Pd Otek te wee 23 Eee Ced ee AAA 1 TU D OST x 124 511 Switch Tgl Dpst 40a 600vac Scr Term 1 TL TR P1 233165 Pot Assy W Leads amp Connector amp
19. A 23 SECTION 10 GUIDELINES FOR TIG WELDING GTAW eeeeee IA 24 DOES P POSHOMING The TOC cR EE 24 10 2 Torch Movement During Welding 205 cee e hs 25 10 3 Positioning Torch Tungsten For Various Weld Joints 25 SECTION 11 PARTS EIST S sawnt det ni e ee ee oe RE A Ai 26 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2009 07 Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided DANGER Indicates a hazardous situation which if could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install op
20. Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor FF FF F F X FF FH FHF HF HF HF X Subarc Wire Drive Assemblies 4 6 Months Batteries Miller 5 90 Days Parts MIG Guns and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipm
21. Diameter DCEN Argon Direct Current Electrode Negative For Use With Mild Or Stainless Steel AC Argon Balance Control 65 Electrode Negative For Use With Aluminum 010 1 mm 020 1 mm 040 1 mm 1 16 1 6 mm 3 32 2 4 mm 1 8 3 2 mm 5 32 4 0 mm 3 16 4 8 mm 1 4 6 4 mm 2 Ceria Orange Band 1 5 Lanthanum Gray Band Or 2 Thoriu Up to 25 15 40 25 85 50 160 135 235 250 400 400 500 500 750 750 1000 m Red Band Alloy Tungstens Up to 20 15 35 20 80 50 150 130 250 225 360 300 450 400 500 600 800 Typical argon shielding gas flow rates are 11 to 35 cfh cubic feet per hour Figures listed are a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers 9 2 Preparing Tungsten Electrode For DC Electrode Negative DCEN Welding Or AC Welding With Inverter Machines a 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 information Consider using tungsten containing ceria lanthana or yttria instead of thoria Grinding dust from thoriated electrodes contains low level radioactive material Properly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flammables away Radial Grindi
22. dde none me de be nap ar une dot ee de PR HR ND ig a 14 4 5 Connecting Input Power 25 4 x wide pen Red Net s CR RE Wea eee ead Ee pn d ON Ss mac RR 15 SECTION 5 OPERATION feia E E HE Rae datu Re e eb mE SOT ers VES ERE DEN a 16 oS o PORTER di D RR E wee sen 16 SECTION 6 MAINTENANCE AND TROUBLESHOOTING eee nnns 18 6 1 Routine MAINIGRANCE x xe iba edoceri ce Sod SOUS OR eee Dose ole Ee eh AR n debeo E WS e dene 18 6 2 Circuit Breaker GB 1 zu aies ce m t RC o cr on a De c Ae Race C ac ab aye I Ee 18 6 3 MOUDIGSHOOUNG uus ose dos d ce om ake Rub ace ea ceci ste P ttd Mee eae fee b asl seers oa ee x 19 SECTION 7 ELECTRICAL DIAGRAM 00 c cece cece eee n hh hh hh hh hm 20 SECTION 8 HIGH FREQUENCY 1 pcr ike RE IR dew a re ie Rea s 21 8 1 Welding Processes Requiring High Frequency 2 21 8 2 Incorrect Installallgby s suce aste mE Rer Dawes sexi a eure EE RU ins dc dcs d due Sube B dox sacs d 21 8 3 Correction sai ape te en e ts di dr quotus dad ax dE pape qtd 22 SECTION 9 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES Meer 23 9 1 Selecting Tungsten Electrode Wear Clean gloves To Prevent Contamination Of Tungsten 23 9 2 Preparing Tungsten Electrode For DC Electrode Negative DCEN Welding Or AC Welding With Inverter Machines css ea ek mx ens SO x as Ri m e dace Ds io eorura Unda d ea Lais MO
23. in the AC position use the gray scale to select the appropriate material thickness and corre sponding amperage from the white scale The AC parameters have been optimized and auto matically set POWER MAX OUTPUT MATERIAL 1 Preflow is preset at 2 seconds for DC or AC NENNT Postflow is preset for one second for every ten amps of output with a minimum of eight sec onds for DC or AC 3 Power Switch Use switch to turn unit On and Off 4 Power On LED Power is on when LED is lit LED flashes when input power is more than 10 of 230 volts No output available when LED is flashing 5 Output Indicator LED A P F p JUYN Si J F Y EN N X Y Q Output is On when LED is lit LED flashes when unit is overheated see Section 3 5 LED stops flashing when unit has cooled F F f NI NINISN f GIN EN OO 805 163 A 232 896 OM 232 895 Page 16 6 Torch Torch Operation 7 Amperage Adjustment Wheel Use wheel to adjust amperage from ten amps to maximum value set on the machine s Material Thickness Amperage Control 8 On Off Switch Switch has three features that con trol the machine in different ways e Trigger hold Push and release On Off switch to start welding Af ter switch is released the Amper age Adjustment wheel can be ad justed to ramp amperage to de sired value for the material being welded To end weld sequence push and release switch Tac
24. l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endom mag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot gerles bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Lecouvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu e
25. nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chal
26. other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW Cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep weldi
27. some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in SU oA ba cad exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web ur Miller Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad O MPSS RACER Rae wee Ke iad ed tute abad een ade taney 1 152 Are Welding Hazardo 3 orsus ae oe ale o ar de a a uim deu ade a eee ees 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 1 4 5s P ncipal Satety Standards enterarte arroz AU 4 156 EME IBITOFITIS BOTE su auci ai dar n c acr 8 to ata dica is 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION
28. 4 14 Reference 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 232 895 Page 14 4 5 Connecting Input Power A Installation must meet all Na tional and Local Codes have only qualified persons make this installation A Disconnect and lockout tag out input power before con necting input conductors from unit A Always connect green or green yellow conductor to supply grounding terminal first and never to a line termi nal 6 S5 GND PE Earth Ground 1 Rating Label Supply correct input power see Sec tion 4 4 2 Black And White Input Conductor L1 And L2 3 Green Or Green Yellow Grounding Conductor 4 Input Power Cord 5 Disconnect Device switch shown in the OFF position 6 Disconnect Device Grounding Terminal 7 Disconnect Device Line
29. ASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin 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
30. Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 8 Over Current Protection Select type and size of over current protection using Section 4 4 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout de vice and place switch in the On posi tion 9 Plug NEMA 6 50P 10 Receptacle NEMA 6 50R Connect plug to receptacle A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 230 VAC 1 v Tools Needed n Ref 805 116 A OM 232 895 Page 15 SECTION 5 OPERATION 5 1 Controls Material Switch 1 A Do not use AC output in damp areas if movement is confined or if there is danger of falling Use AC output ONLY if required for the welding process and then use a remote control A Do not change position of switch while welding or while under load Use switch to select DC for steel stainless steel and chrome moly or AC for aluminum applications 2 Material Thickness Amperage Control Use control to select material thickness and corresponding amperage When Material switch is in the DC position use the blue scale to select the appropriate materi al thickness and corresponding amperage from the white scale When Material switch is
31. afety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department ORIGINAL INSTRUCTIONS PRINTED IN USA C 2009 Miller Electric Mfg Co 2009 01 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 amp Canada FAX 920 735 4134 International FAX 920 735 4125 For International Locations Visit www MillerWelds com GQ Miller
32. associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit NEZ FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle
33. avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l ou on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil utilisation d une source lectrique a courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants 7 Indique des instructions sp cifiques Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger dans l ordre indiqu 1 un poste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste
34. d undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of inputpower e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns iiim OM 232 895 Page 1 FUMES AND G
35. d worktable 2 Center Point of Welding Zone Midpoint between high frequency source and welding torch 3 Welding Zone A circle 50 ft 15 m from center point in all directions 4 Weld Output Cables Keep cables short and close together OM 232 895 Page 22 Ground workpiece if required by codes 5 Conduit Joint Bonding and Grounding Electrically join bond all conduit sections using copper straps or braided wire Ground conduit every 50 ft 15 m 6 Water Pipes and Fixtures Ground water pipes every 50 ft 15 m 7 External Power or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone lines 8 Grounding Rod Consult the National Electrical Code for specifications Metal Building Requirements 9 Metal Building Panel Bonding Methods Bolt or weld building panels together install copper straps or braided wire across seams and ground frame 10 Windows and Doorways Cover all windows and doorways with grounded copper screen of not more than 1 4 in 6 4 mm mesh 11 Overhead Door Track Ground the track SECTION 9 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2007 05 o A Whenever possible and practical use DC weld output instead of AC weld output 9 1 Selecting Tungsten Electrode Wear Clean gloves To Prevent Contamination Of Tungsten Amperage Range Gas Type Polarity Electrode
36. dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci a propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes 25 West 43rd Street New York NY 10036 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents
37. dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 232 895 Page 8 LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e nergie lectromagn
38. e is installed and grounded according to this manual e lf interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 232 895 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA
39. e safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e Toreduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machin
40. ed 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 Trouble Remedy No weld output unit completely inoperative Place machine power switch in On position see Section 5 1 Place line disconnect switch in On position see Section 4 5 Check and replace line fuse s if necessary see Section 4 5 Check for proper input power connections see Section 4 5 No weld output unit on Check repair or replace remote control Have Factory Authorized Service Agent check unit Unit provides only maximum or minimum weld output Make sure Material Thickness amperage control is in proper position see Section 5 1 Have Factory Authorized Service Agent check unit Erratic or improper weld output Lay weld cables out straight do not leave weld cables coiled Check position of Material Selector switch see Section Figure 5 1 Check position of Material Thickness amperage control see Section 5 1 No control of weld output Make sure Material Thickness amperage control is in proper position see Section 5 1 Lack of high frequency difficulty in starting GTAW arc Select proper size tungsten see Section 9 1 Be sure torch cable is not close to any grounded metal Check cables and torch for cracked insulation or bad c
41. en ordering parts from your local distributor OM 232 895 Page 29 Notes Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor 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 questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way Effective January 1 2009 Equipment with a serial number preface of LK 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 conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will prov
42. ent which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Millers option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS
43. erate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground Fo
44. eur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant l soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc OM 232 895 Page 6 e Porter des v tements confectionn
45. ge NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds LA CHUTE DE L QUIPEMENT peut L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement res pecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES PROJET ES peuvent provoquer des blessures LA e Porter un cran facial pour prot ger le visage el les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette man uvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable P 4 Q S a oa LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 232 895 Page 7 Les PIECES MOBILES peuvent causer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des ble
46. ide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers only to include SCRs diodes and discrete rectifier modules 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Fume Extractors Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma
47. ion can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards e Do not use welder to thaw frozen pipes OM 232 895 Page 2 Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS can injure or kill
48. king Fitting Feature Press and hold On Off switch for more than one second to start weld out put Release switch to end weld output This feature is useful for tacking and fitting or in other situ ations when weld output is need ed for short periods of time Crater Out Feature Press and hold On Off switch at end of weld sequence to ramp weld amper age down until arc is extin guished Use this feature at the end of the weld sequence to help fill the crater that can form in the weld puddle 9 Optional Foot Control This is a dedicated foot control which can be purchased as an ac cessory When the optional foot control is plugged into the Remote Recep tacle see Section 4 2 the fingertip control on the torch is disabled 805 059 A 805 158 A OM 232 895 Page 17 SECTION 6 MAINTENANCE AND TROUBLESHOOTING 6 1 Routine Maintenance D y Check Change Clean A Repair x Replace To be done by Factory Authorized Service Agent Every 3 Months Gas Hoses Every 3 Months Cables And Cords AS Every 6 Months Ne Z Q Durning heavy service clean monthly 6 2 Circuit Breaker CB1 1 Circuit Breaker CB1 If CB1 opens unit will be completely inoperative If CB1 opens repeatedly have a Fact ory Authorized Service Agent check unit 805 395 A OM 232 895 Page 18 6 3 Troubleshooting E7 The remedies list
49. lle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance gt Risque D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service provoquer des blessures e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement cables et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivre les consignes du Manuel des applications pour l quation de leva
50. ng Causes Wandering Arc o 2 1 2 Times Electrode Diameter NO T E Pus O Wes 1 Grinding Wheel Grind end of tungsten on fine grit hard abrasive wheel before welding Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality 2 Tungsten Electrode A 296 ceriated tungsten is recommended 3 Flat Diameter of this flat determines amperage Ideal Tungsten Preparation Stable Arc capacity 4 Straight Ground Grind lengthwise not radial OM 232 895 Page 23 SECTION 10 GUIDELINES FOR TIG WELDING GTAW 10 1 Positioning The Torch OM 232 895 Page 24 Sec EL AC I Y o S 1 16 in Bottom View Of Gas Cup A 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 information Consider using cerium or lantha num based tungsten instead of thoriated Thorium dust contains low level radioactive material Properly dispose of grinder dust in an environmentally safe way Wear proper face hand and body protection Keep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Section 9
51. ng power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2009 07 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte A DANGER Indique une situation dangereuse qui si on Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter t
52. ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES wack SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuvent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter
53. onnections Repair or replace Wandering arc poor control of direction of arc Reduce gas flow rate see Section 4 3 Select proper size tungsten see Section 9 1 Properly prepare tungsten see Section 9 2 Tungsten electrode oxidizing and not remaining bright after conclusion of weld Shield weld zone from drafts Check and tighten all gas fittings Properly prepare tungsten see Section 9 2 Fan not operating Unit equipped with Fan On Demand Fans run only when necessary Unit equipped with circuitry to protect against overheating No weld output fan does not run Place line disconnect switch in On position see Section 4 5 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 5 Check for proper input power connections see Section 4 5 No weld output fan on Be sure Material Selector switch is set in position see Section 5 1 Check connection to remote control receptacle see Section 4 2 Check remote control see remote control Owner s Manual Unit overheated Allow unit to cool see Section 3 5 Fan not operating weld output available Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Power LED flashes Input voltage out of usual range of 230 volts 10 Output On LED flashes Unit has overheated Do not use until LED
54. out risque Les instructions en mati re de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil A Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ues en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique
55. r these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards 7 Indicates special instructions e a A This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damage
56. s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection gt n LE SOUDAGE peut provoquer un TER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusementavec des protections homologu s e Ne pas souder dans un endroit l ou des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t
57. ssures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage Les PIECES MOBILES peuvent causer des blessures qu e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua lifi Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des mal formations cong nitales et
58. stops flashing see Sections 3 5 and 5 1 OM 232 895 Page 19 SECTION 7 ELECTRICAL DIAGRAM S1 BLK 11 BLK 12 CBI GRN RED RED Li a a RED BLUE BLK 9 RED D mx O L1 1 O Li e lt RC8 1 Q CHASSIS 1 CHASSISe 1 CHASSIS3 1 Pri Thermistor lt RC8 e C RC4 1 C RC4 7 lt RC1 4 lt Rc1 5 lt RC2 1 C RC2 2 Gas Valve 24vdc Fan 24VDC PCI RC1 PLG1 RC2 PLG2 RC3 PLG3 RC4 PLG4 RC5 PLGS RC7 PLG7 RC8 PLG8 F1 2 1 SS en Hf control pulse traln RCL 2 gt e AN common RCL3 gt V Vy 5vdc Master pot common P EN Remote pot RC5 e gt Com 15VDC CONTACTOR RCS 6 gt x T1 1 O T1 2 O FOOT CONTROL HOV RC731 gt REMOTE POT RC7 2 gt CUM RC7 3 gt 45V RC7 4 gt FOOT SELECT Rc7 5 gt CONTACTOR IR1 MATERIAL a Q 1 A y a z a WU y e F2 A 4 E RCi 1 PC3 i RC1 PLG31 i RC1 3 THICKNESS AMPERAGE POT CL POWER GREEN se Q MATERIAL O CPOLARITY SWITCH TO TORCH 4 5 me SL euw M CM Re7 7 S UN AI RC6 1 2 ers TRANSFORMER SECONDARY WINDING F3 RC6 3 gt RC3 OM 232 895 Page 20 WARNING ELECTRIC SHOCK HAZARD 1 Polarity for EN 2 Polarity Common 4 COM 5 H5V 6 15V 7 IFB 1V 25A 1e 13 18V_DC 14 18V_ DC 15 18VDC CDM 16 18V DC CUM 17 18 19 TORCH 20 WORK Do not touch live electrical parts
59. tales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association Quincy MA 02269 t l phone 800 344 3555 site Internet www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 t l phone 703 788 2700 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS t l phone 800 463 6727 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard 287 1 de American National Standards Institute 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou
60. th Plug Gas Hose Gas Regulator 12 ft 3 7 m Work Cable With Clamp Air Cooled 150 Amp TIG Torch with 12 ft 3 7 m Cable 7 Some assembly is required For options and accessories see back of book or contact your dis tributor 805 114 A 3 2 Specifications Rated Output at 20 Rated Input Welding Mode Duty Cycle 60 HZ Single Phase KVA KW Amperage Range Max OCV AC 150 Amps at 16 Volts 230 V 21A 64 4 9 04 3 6 02 10 165 80 DC 150 Amps at 16 Volts 230 V 23 A 50 5 3 04 3 9 02 10 165 80 While idling 3 3 Serial Number And Rating Label Location The serial number and rating information for the power source is located on the rear of the machine Use the rating labels to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual OM 232 895 Page 11 3 4 Dimensions And Weights a 23 15 16 in Dimensions 608 mm Height 17 in A33 mm Width 9 88 in 251 mm 23 93 in 608 mm w handles Length 19 25 in 489 mm w o handles 251 mm ho a Ref 805 114 A Weight 50 Ibs 23 kg 3 5 Duty Cycle Chart Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty z pum 8 EA EA E EA EA 2 p pu
61. the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection FRA WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partit
62. uit Foot Select 5 Foot control select jumper to 7 in foot control 7 Chassis common OM 232 895 Page 13 4 3 Shielding Gas Connections E7 Use argon shielding gas for best performance 1 Cylinder Valve Open valve slightly so gas flow blows dirt from valve Close valve Tools Needed 2 5 8 1 1 8 in 2 HRegulator Flow Gauge Connect regulator flow gauge to gas cylinder Do not over tighten Connect gas hose to gas in fitting 3 Flow Adjust Typical flow rate is 20 cfh cubic feet per hour Ref 805 114 A 4 4 Electrical Service Guide E All values calculated at 20 duty cycle C7 Actual input voltage cannot exceed 10 of indicated required input voltage shown in table If actual input voltage is outside of this range damage to unit may occur A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source 60 Hz Single Phase Input Voltage 230 Volts VAC 230 Volts VAC Process AC TIG DC TIG Input Amperes At Rated Output 21 23 Max Recommended Standard Fuse or circuit breaker Rating In Amperes 1 Time Delay 25 30 Normal Operating 30 35 Min Input Conductor Size In AWG 14 14 Max Recommended Input Conductor Length In Feet Meters 70 21 64 20 Min Grounding Conductor Size In AWG 1

DIVERSION 165 - Rapid Welding and Industrial Supplies Ltd

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