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Miller Electric MARK VIII-2 User's Manual

1. OM 218 Page 26 ELECTRIC SHOCK HAZARD Disconnect input power or stop engine before servicing 6 Do not operate with covers removed Have only qualified persons install use or service this unit Figure 7 1 Circuit Diagram For Polyweld System UI P M HYT R le le k ER n Ka Hi Ci Kl N o N IN IN R NON N NON N R NW go LS AMPERAGE AMPERAGE S S IN AMPERAGE S S IN ge AMPERAGE i 36 ADJUSTMENT A 36 ADJUSTMENT i 3GADJUSTMENT i ZGADJUSTMENT RC11 RC21 RC31 RC41 MATI GRB C MA21 GR B C MASI GR B C MAA1 GR B C 51 51 51 5f 37 37 CWD CWD ae CWA RMT sm CWA STD CWA u SID CWA ED STD s13 S23 S33 S43 CF CF JO E E EI c14 em C24 c21 C34 C31 c44 C41 C cs C ci C y cs rm kj o _k kK lt lt Ho ha HH D14 D11 D24 D21 D34 D31 D44 D41 c15 c12 c25 c22 c35 c32 c45 c42 tu E k 53 tt lt a 53 kK lt a ST HH lt 231 KH D15 D12 D25 D22 D35 D32 D45 D42 SR11 SR21 SR31 SR41 c16 c13 C26 C23 C36 C
2. 1 el OE Re idea es 181246 TERMINAL pwr output black 1 M la ve CB11 083432 SUPPLEMENTARY PROTECTOR man reset 1P 10A 250V 1 rr Sak RIT 222 736 RHEOSTAT WW 150W 15 ohm 1 ME ars Sak RC11 039607 RECEPTACLE twlk 3P3W 20A 250V 1 od SL ON Cor A Nes 605 797 PLUG twlk 3P3W 20A 120V Arrow Hart 6312 Ix d sce Binns etn 010828 HANDLE Ree teet a Ue ue tere oen ru dV Ode Eee we 1 mod od 097 926 KNOB pointer 00 ccc en ee ee ee ee ee 1 Hardware is common and not available unless listed ST 155 304 C Figure 10 3 Panel Front Module w Components Recommended Spare Parts 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 218 Page 36 Item Dia Par No Mkgs No Description Quantity Figure 10 4 Panel Front Lower w Components Fig 10 1 Item 25 TA ELE N 086 855 PANEL front lower 1 De RE es a 217 136 LABEL warning electric shock 1 iS visu eaa OE 174847 LABEL general precautionary 1 AA DREN ddr eit es 004 449 RING spacer switch 2 no
3. 17 4 8 Remote Contactor Control Connections Optional 17 4 9 115 Volts AC Duplex Receptacle 18 4 10 Connecting Input Power 18 4 11 Electrical Service Guide 20 SECTIONS5 OPERATION 2 422 EERDER iim GERS EERS DER SES PES EER GEE EER ee DE EER DE eg 20 5 1 ee ie AE ET EE EE EE OE EER 20 5 2 Amperage Adjustment Controls 21 5 3 Power Switch Push Buttons And Pilot Lob 21 SECTION 6 MAINTENANCE amp TROUBLESHOOTING euu 22 6 1 Routine Maintenance ENEE kh eee a bia 22 6 27 Overload Protection xit eaves egg ee Dea en eae he eee lee aes 22 6 3 Blank Module Panel EE RER dr br Pe baa ER EE ede OER ER ER ee cede renee 23 6 4 Troubleshooting x u 2 view eevee ee SE ag hein EE gone dad ee ede 24 SECTION 7 ELECTRICAL DIAGRAM ee ee ee cece eee Re Re I eee nn nn nn nn nn nennen 26 SECTION 8 SELECTING AND PREPARING TUNGSTEN ELECTRODE ki fies lee nep A aaa ha a EMEN d 28 8 1 Selecting Tungsten Electrode 28 8 2 Preparing Tungsten For AC Or DC Electrode Positive DCEP Welding 29 8 3 Preparing Tungsten For DC Electrode Negative DCEN Welding 29 SECTION 9 GUIDELINES FOR TIG WELDING GTAW
4. 6 BA IE A IE 087318 CLAMP stl cush 1 000dia x 203mtg hole 6 202 dE EE 128 492 TRANSFORMER pwr main 230 460 575 includes 1 agitate dws TP1 026 181 HERMOSTIATNCG 1 20 25 TE eats 128493 TRANSFORMER pwr main 220 380 440 includes 1 Bs sre the nue TP1 026181 THERMOSTAT NC 1 AB ne OE EO 173513 SCREEN front upper 1 SEA veis ur e di Fig10 3 PANEL front module w components 8 ME SR a Fig 10 1 PANEL front lower w components 1 rp pe AE E AE 603 732 NUT brs hex 750 10 full hvy 2 SPORE EE 217 733 LABEL warning electric shock 8 input power EN FR 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 218 Page 33 rdware is common and le unless li A a lop PEL DIT TA Figure 10 2 Main Assembly Section B Item Dia Part No Mkgs No Description Quantity Figure 10 2 Main Assembly Section B a CR1 194307 CONTACTOR def prp 40
5. 00 cece ee ee see ee ee ee ee ee ee ee ee ee 30 9 1 Positioining UC ee ENEE 20 9 2 Torch Movement During Welding 30 9 3 Positioning Torch Tungsten For Various Weld Joints 31 SECTION 10 PARTS LIST cor a a ada aaa Rd 32 Notes SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som _3 05 A Warning Protect yourself and others from injury read and follow these precautions 1 1 A Symbol Usage Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Marks a special safety message EF Means Note not safety related 1 2 Arc Welding Hazards A A A rd 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 operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal
6. OM 218 029 920Z July 2005 Miller TIG GTAW Welding Stick SMAW Welding LS Air Carbon Arc CAC A Cut W ing and Gouging With Optional Equipment MIG GMAW Welding A fe Flux Cored FCAW Welding d FC Air Plasma Cutting and Gouging Description E pz E3 Arc Welding Power Source MARK VIII 2 C OWNERS 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 n U a Bl E PEENI 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 Working as hard as you do every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve m
7. WASHER lock stl split 375 8 EU EHEN 038 804 STUD brs 375 16 x 2 500 8 NT RE 010913 WASHER flat brs 218 ID x 460 OD x 031thk 4 8 F11 82 012 237 FUSE PANEL module includes 4 SEN A 038888 STUD pri bd brs 250 20 x 1 500 10 A Se RE 038 205 4 PANEL ee 23 EER DR a Re ee te a nee A ETE ee 010915 WASHER flat brs 250 ID x 625 OD x 031thk 10 AAA a 601 836 NUT brs hex 250 20 jam hvy 14 GE SN 012 207 FUSE link 200A 250V 4 E 602241 WASHER flat st SAE 250 4 O ER HERR 602 207 WASHER lock stl split 250 4 ER a 601835 NUT brs hex 10 32 4 ton 010913 WASHER flat brs 218 ID x 460 OD x 031thk 4 Der ee pe End Ma 038 887 STUD pri bd brs 10 32 x 1 375 A EMO EE Seen EOS 177 711 INSULATOR cover fuse 4 D p Woo 099 044 CONTACTOR sz 3 1 2 3P 110 120 220 240 includes 1 EE e 048 599 COIL cntor 115 230V sz 3 1 2 1 E or T2 144589 TRANSFORMER kVA 2 115 230 460
8. e Porter des lunettes de s curit avec crans lat raux m me sous vo tre 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 Porter des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un RIZ incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels DES PIECES CHAUDES peuvent provoquer des br lures graves Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures 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 peuvent provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de LES CHAMPS MAGN TIQUES peuv
9. Tools Needed C IRA 3 8 1 2 in ST 800 479 ST 155 300 6 3 Blank Module Panel FA 2 A Turn Off polyweld system and disconnect input power ES before inspecting maintaining or servicing A blank module panel is included with each polyweld system If a module is removed install the blank module panel in the location where the module was removed before using the remaining modules This panel prevents the touching of inside parts and wires and ensures proper air flow through the polyweld system OM 218 Page 23 6 4 Troubleshooting Te D 9 A Turn Off polyweld system and disconnect input power ES Ze J before inspecting maintaining or servicing e Trouble Remedy No weld output from any module fan motors off pilot light off Place line disconnect device in On position see Section 4 10 Check line fuse s and replace if needed Reset circuit breakers see Section 4 10 Check for proper input connections see Section 4 10 Check position of input voltage jumper links see Section 4 10 Be sure power switch is On see Section 5 3 Check fuse F3 and or F4 and replace if needed see Section 6 2 Have Factory Authorized Service Station Service Distributor check Start Stop push buttons PB1 PB2 and replace if necessary No weld output from any module fan motors on pilot light off Thermostat TP1 open overheating Allows fans
10. S Ee AMPERAGE A ADJUSTMENT A 3GADJUSTMENT A 36ADJUSTMENT i 36 ADJUSTMENT RC51 RC61 RC71 mS RCB1 GR B C GR B C GR B C GR B C 51 57 57 51 37 37 37 I7 CWA aD CWA SD CWA ch CWA RMT ua S53 S63 S73 S83 E JO JO E C54 C51 C64 C61 C74 CH c84 C81 is Kit is un is cr is C071 _k ALA dk X A KA _k tt D54 D51 D64 D61 D74 D71 D84 D81 C55 C52 C65 C62 C75 C72 c85 c82 E Cc tE c Es k AN AA 37 E KEI 27 AE lt ME AE D55 D52 D65 D62 D75 D72 D85 D82 SR51 SR61 SR71 SR81 C56 C53 C66 C63 C76 C73 C86 C83 Ki A SL Kd KI GE 4 Kt K4 424 1 Ki EDS Ki pse WR D53 pee PI D63 pe PI D73 pae R I D83 La La 24 25 24 25 24 j 25 24 25 R52 26 R62 26 R72 26 R82 Z6 3 251 3 z61 3 zn z81 29 29 29 29 GND o Q O o O O O o SD 082 527 C OM 218 Page 27 SECTION 8 SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw 7 97 NOTE gt contamination of tungsten electrode For additional information see your distributor for a handbook on the Gas Tungsten Arc Welding GTAW process Wear clean gloves to prevent 8 1 Selecting Tungsten Electrode Amperage Range Gas Types Polarity Electrode Diameter DC Argon Electrode Negative Straight Polarity DC Argon Electrode Positive Reverse Polarity AC Argon Using High Frequency AC Argon Balanced Wave Using
11. If Applicable 5 Tungsten Electrode Select and prepare tungsten according to Sections 8 1 and 8 2 or 8 3 Tungsten extension is the distance the tungsten extends out gas cup of torch Arc length is the distance from the tungsten to the workpiece As a general guide start with an extension and arc length equal to diameter of tungsten ST 161 892 9 2 Torch Movement During Welding Tungsten Without Filler Rod o Welding direction e 75 lt lt U 1 Y LID LD Z ZZZ A Z Z A Form pool Tilt torch Move torch to front of pool Repeat process Tungsten With Filler Rod EE 75 o Welding direction 15 I 1 Z ZZZ Z Z LE A Form pool Tilt torch Add filler metal TT e Z ZARZA V TITI Remove rod Move torch to front of pool Repeat process ST 162 002 B OM 218 Page 30 9 3 Positioning Torch Tungsten For Various Weld Joints 90 Butt Weld And Stringer Bead I L 70 v Jj 20 20 T Joint D e 70 Y 20 10 40 Lap Joint Se 270 Es 20 30 90 Corner Joint N ST 162 003 S 0792 OM 218 Page 31 SECTION 10 PARTS LIST Figure 10 1 Main Assembly Section A OM 218 Page 32 Item Dia Part No Mkgs No Description Quantity Fig
12. e Do not touch electrode holders of opposite polarity at the same time Separate electrode holders of opposite polarity to prevent contact e Consult ANSI Z49 1 for common grounding safe practices OM 218 Page 14 A Standard Module Connections A READ SAFETY BLOCKS at start of Section 4 6 before proceeding INADEQUATE WORK CABLE CONNECTIONS can cause serious damage to input power service and create a hazardous condition Connect an electrical cable of adequate size between the common work connection terminal and the workpiece whenever any mod ule s is connected to use the frame connection terminal and the common work connection terminal AA HII Separate Work Connections Common Work EE Connections A For common work connection work cable must be able to carry combined weld output of all modules using the common work connection terminal see Table 3 1 for proper cable size When using the common work con nection terminal all connections to the common work connection terminal must be of the same polarity Tools Needed SEEP 1 1 4 in 1 Cable Restraint Route all cables under cable restraint Separate Work Connections See Section 4 4 for proper cable size 2 Negative Weld Output Terminal 3 Work Cable Positive Weld Output Terminal 5 Electrode Holder Cable For Electrode Positive Reverse Polarity DCEP connect work cable to Negative terminal and el
13. 575 1 tee opm TE aways 144590 TRANSFORMER kVA 2 115 220 230 380 440 50 Hz 1 aa ida 015 722 GROMMET rbr 1 250 ID x 1 500mtg hole 2 Recommended Spare Parts 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 218 Page 35 Item Dia Par No Mkgs No Description Quantity Figure 10 3 Panel Front Module w Components Fig 10 1 Item 24 ud E eens 034 253 DOOR access pwr output includes 1 ME den ee 032 477 INSULATOR cover secondary 1 d gia ats 038978 LINK jumpet uoo geht a Rei nt 1 WC PTT 026 758 BOOT circuit breaker 1 ANS Ae de A 177618 PLATE front module 50 60 HZ models 1 DE N OE 174 143 PLATE front module 60 HZ models 1 E PE 098899 PANEL front module 1 sd Lie SR12 035704 RECTIFIER integ 40A 800V 1 e e uisus S13 011609 SWITCH tgl SPDT 156A 125VAC 1 EE Ed 181 245 TERMINAL pwr output red 1 N WE sti A 182665 TERMINAL pwr output neutral
14. Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les c bles ensemble en les tordant ou en les enveloppant 2 Disposer les cables d un c t et a distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas 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 sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m de cin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 SPECIFICATIONS 3 1 Specifications Rated Welding Output For Main Rated Welding Output For Each Amperes Input at Rated Load Output 60 Hz Three Phase Transformer Module Max OCV DC 220V 230V 380V 440V 460V 575V KVA KW 800 40 Volts DC 100 Duty Cycle 200 40 Volts DC 80 178 170 103 89 85 68 68 48 6 1600 40 Volts DC 60 Duty Cycle 8 8 5 4 4 3 2 3 18 2 65 25 Duty Cycle While idling 3 2 V
15. Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 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 218 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Pra
16. Strip 1T 2 Access Hole Location Drill or punch a hole in lower right rear panel to provide access to terminal strip 1T Hole size should accept standard strain relief connector Install strain relief into access hole 3 Jumper Link Remove jumper link 4 Lead Connections Route cord through strain relief and connect leads to 1T as shown Polarity is not important Connect leads on other end of cord to a suitable switch Close and secure rear panel ac cess door Ref ST 144 569 B OM 218 Page 17 4 9 115 Volts AC Duplex Receptacle 1 115 Volts AC Duplex Receptacle RC2 This receptacle supplies up to 10 amperes of 115 volts ac power 15V Ay ac 115V Av AC The duplex receptacle is protected 10A OVERLOAD from overload by supplementary BREAKER protector CB1 see Section 6 2 7 1 e C CLOSED Q um OPEN 1 Ref ST 144 570 A Ref SC 085 382 4 10 Connecting Input Power A Positioning Jumper Links E EUM A Turn Off polyweld system and disconnect input power before inspecting or installing 230 VOLTS 460 VOLTS 575 VOLTS e e e e o o o e e o o o o o o o o_o 4 o o Q o o o o o o o o O o o o o o_o e e e e o O o e e o o O o o o o OO 2 TES ARRE TE2 ARAN TES
17. e Le rayonnement haute fr quence HF peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e Lutilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance 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 L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des 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 c bles 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
18. equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce 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 machine is installed and grounded according to this manual e f 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 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 218 Page 3 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 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March
19. haute pression Si une bouteille est endomma g 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 ger les bouteilles de gaz comprim d une chaleur excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom ber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifi que 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 Le couvercle du d tendeur doit toujours tre en place sauf lors que la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les Lire et suivre les instructions sur
20. les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s Symbole graphique d avertissement Attention Cette pro Le c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints A Indique un message de s curit particulier Ce groupe de symboles signifie Avertissement Attention Risques a d p d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures prendre pour supprimer Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce manuel e V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort instructions aff rentes pour viter tout risque Les instructions en e L quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e Ne pas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus compl tes fournies ou mal piss s gans les normes o
21. 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 equipment 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 Miller s 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 E
22. 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 c 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 A Les gaz d chappement des moteurs contiennent des produits chimiques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation A 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 malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l Etat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres p
23. 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 conducteur de mise la terre appropri et contre v rifier les connexions vanis plaqu en plomb ou au cadmium moins que le rev tement 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 toxi ques en cas de soudage OM 218 Page 5 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 RAYONS D ARC peuvent entrai ner des br lures aux yeux et la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants ap propri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit
24. 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground 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 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 For 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 vo
25. symbols at start of Section 9 1 before preparing tungsten Ball end of tungsten before welding by applying either an ac amperage slightly higher than what is recom mendedfor a given electrode diam eter see Section 8 1 or a dc 2 electrode positive amperage e S EE 1 1 2 Times _ Electrode Diameter Ref S 0161 8 3 Preparing Tungsten For DC Electrode Negative DCEN Welding h 1 Tungsten Electrode a 1 2 2 Tapered End Grind end of tungsten on fine grit hard abrasive wheel before weld ing Do not use wheel for other jobs 2 E or tungsten can become contami L nated causing lower weld quality 2 1 2 Times Electrode Diameter 1 Stable Arc 2 Flat d Diameter of this flat determines Sa amperage capacity 3 Grinding Wheel S z gt 4 Straight Ground 75 Ideal Tungsten Preparation Stable Arc 1 Arc Wander 2 Point 1 3 Grinding Wheel 4 Radial Ground ds UL 2 ARE A 4 Wrong Tungsten Preparation Wandering Arc Ref S 0161 Ref S 0162 OM 218 Page 29 SECTION 9 GUIDELINES FOR TIG WELDING GTAW 9 1 Positioining The Torch A 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 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
26. the same output Securely cover con nection with proper insulating material A For common work connection work cable must be able to carry combined weld output of all modules using the common work connection terminal see Table 3 1 for proper cable size When using the common work con nection terminal all connections to the common work connection terminal must be of the same polarity 1 Cable Restraint Route all cables under cable restraint Separate Work Connections See Section 4 4 for proper cable size 2 Negative Weld Output Terminal Electrode Holder Cable Positive Weld Output Terminal 5 Work Cable 6 Connection Point For Electrode Negative Straight Polarity DCEN connect separate cables of same size and length from Positive terminals to the work or to a suitable connection point con necting to a single work cable Connect separate cables of same size and length from Negative terminals to a suitable connection point connecting to a single elec trode holder cable For Electrode Positive Reverse Polarity DCEP reverse cable con nections Common Work Connections 7 Common Work Connection Terminal 8 Common Work Cable See Table 3 1 for proper size cable 9 Frame Connection Terminal 10 Jumper Link For Electrode Negative Straight Polarity DCEN connect jumper link across Positive terminal and Frame Connection terminal for each paralleled module Connect separat
27. to cause cancer and birth defects or other reproductive harm Wash hands after handling P MOVING PARTS can cause injury Keep away from moving parts such as fans CA e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts 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 The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e If 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
28. to run thermostat closes when unit has cooled see Section 6 2 No weld output from any module fan motors on pilot light on Have Factory Authorized Service Station Service Distributor check contactor W and replace if needed Limited output and low open circuit volt age from All modules Check incoming power for correct voltage Replace line fuse if open or reset circuit breaker see Section 4 10 Check position of input voltage jumper links see Section 4 10 No weld output from one module only Check fuse links and replace if needed see Section 6 2 Low weld output from one module only No amperage control Place Remote Amperage control switch in Off position or connect remote amperage control to Remote Amperage Control receptacle see Section 5 2 Check module fuse link and replace if needed see Section 6 2 Reset module supplementary protector see Section 6 2 Module thermostat open overheating Allow module to cool down thermostat closes when module has cooled see Section 6 2 Erratic weld output Tighten all weld cable connections see Section 4 6 Check for proper size and type of cable see Section 4 10 Check for proper input and output connections see Sections 4 10 and 4 6 Use dry properly stored electrodes No weld output at 115 volts ac duplex receptacle Reset overload supplementary protector CB1 see Section 6 2 Check fuse F
29. welding ma chines at the same time since double open circuit voltage will be present 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 Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES 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 Work in a confined space only if it is well ventilated or while wearing a
30. 111 1 Li TE2 12155101 TES AECH TE2 CET S 006 233 A 440 VOLTS 082 263 A Jumper links allow operation on differ ent input voltages and are factory set for the highest input voltage Check input voltage available at site Open rear panel access door to check jumper links 1 Input Voltage Label Look at jumper links and compare link position with unit label Only one label will be on unit 2 Input Voltage Jumper Links Move links to match input voltage For example use 230 volts position when 230 volts input power is available Close rear panel access door or go on to Section 4 10B Tools Needed m CO 3 8 1 2 in ssb5 1 2 92 Ref ST 144 569 B OM 218 Page 18 Connecting Input Power C Tools Needed ER 1 1 16 in CARA 3 8 in A Installation must meet all National and Local Codes have only qualified per sons make this installation A Disconnect and lockout tagout input power before connecting input con ductors from unit Make input power connections to the welding power source first A Always con
31. 3 Months Clean And Tighten Weld Terminals Replace Cracked Cables 10 Replace Unreadable Labels A Turn Off polyweld system and disconnect input power before inspecting maintaining or servicing ad 6 Months Blow Out Or Vacuum Inside During Heavy Service Clean Monthly Fan Motor Sealed Bearings No Oil Needed TA ST 144 567 A 6 2 Overload Protection A Overload Supplementary Protector CB1 And Module Supplementary Protectors CB11 Through CB81 R Wer A Turn Off polyweld system and dis connect input power before inspect ing maintaining or servicing 1 Overload Supplementary Protecotr CB1 Supplementary protector CB1 pro tects the 115 volts ac windings of control transformer T3 from over load If CB1 opens the 115 volts ac duplex receptacle RC2 would not work Manually reset CB1 2 Module Supplementary Protectors CB11 Through CB81 The control circuitry in each of the eight modules is protected from overload by a supplementary pro tector CBX1 X represents the number of the applicable module 1 8 If a module supplementary protector opens output from the affected module would drop to mini mum and can not be regulated Manually reset the affected protector 115V Ay AC 115
32. 3 and or F4 and replace if needed see Section 6 2 Fan motor s does not run when On push button is pressed Check fuse F3 and or F4 and replace if needed see Section 6 2 Have Factory Authorized Service Station Service Distributor check control relay CR1 and fan motor FM1 or FM2 For GTAW wandering arc poor control of direction of arc Select proper size tungsten see Section 8 1 Properly prepare tungsten see Sections 8 2 or 8 3 Tungsten electrode oxidizing and not re maining bright after conclusion of weld Shield weld zone of drafts Properly prepare tungsten see Sections 8 2 or 8 3 Replace torch parts if water has leaked into torch OM 218 Page 24 Notes DECIMAL EQUIVALENTS 015625 di 6 65 se oe se Bei Se 99 ve e 9 660 32 Dez ve e se ee Ze e 9 ve 9 0 Be 6 67 ve CS 6 se Se e o9 ve 0 0 Bez o OM 218 Page 25 SECTION 7 ELECTRICAL DIAGRAM L L o 0 L O TE1 F3 F4 5 6 7 g 3 70 230 460 230V 575V
33. 33 C46 C43 Cc c Cc c E C E k 2 KH lt I KT lt a 2254 KH lt ap ki pie 5H D13 D26 Fa D23 Das VRSL D33 pag VA D43 La 24 25 24 gt 25 24 S 25 24 25 R12 26 R22 26 R32 26 R42 26 3 zi 221 3 z31 3 241 29 29 29 29 o o o o o o o o WARNING le Do not touch live electrical parts TE2 RC2 1 C bU PES a gt D 2 gt 14 o 3ov s am IN zov 30V 30V 3ov zov IN R S amp amp 8 8 N N E KF E BR E RK TO CORRESPONDING MODULES CRI HYT ME i HYT MW HYT ME p Ip Ez 732 N SER MS OOS OS RER 000 9 9 Qi i9 0 TPB1 34 n m m T T m E S 2 S 2 S 43 N N N SR 831 0 0 0 ae H o o 9 o o gt NON IN SINON NON IN R NOS I AMPERAGE N AMPERAGE AMPERAGE N
34. 5 1 Controls 1 Remote Amperage Control 1 2 Switch Module Supplementary Protectors See Section 6 2 Amperage Adjustment Control SEL imm ss 6 e we 6 0 6 o O o O 0 a amp LU U E Ro Nu ELA A N A 0 ST 144 570 A OM 218 Page 20 5 2 Amperage Adjustment Controls 60 Hz Model Shown Control can be adjusted 125 AD while welding 150 Example Of Combination Remote Amperage Control 125 150 100 4 A 75 BIA n 225 Qo Em S 250 35 A 300 Set Switch Set Desired Maximum Amperage Adjust Remote Control 1 Remote Amperage Control Switch For front panel control of a module place switch on that module in Off position For remote control place switch in On position See Example below 2 Amperage Adjustment Control Use control at each module to select weld amperage for that mod ule The numbers are weld amperes 3 Remote Hand Control Min 35 A Max 125 A Ref ST 174 143 5 3 Power Switch Push Buttons And Pilot Light POWER Jon or YT 1 Pilot Light 2 Power On Push Button Press button to turn unit pilot light and fan motors On 3 Power Off Push Button Press button to turn unit pilot light and fan motors Off OM 218 Page 21 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance Ab w See Section 4 6 Dem
35. A 3P 120V 1 La Pen Ange LAA 092 324 TRANSFORMER kVA 1 115 230 460 575 1 dedecus T9 uus 092 322 TRANSFORMER kVA 1 115 220 380 440 50 HZ 1 NC TE ss 038 617 BLOCK term 30A 2P 1 A ENG 038 620 LINK jumper term blk 30A 1 EE ES eae 070 404 HOLDER fuse crtg 30A 600V 1P w clips 2 RED eN ai F3 4 012 664 FUSE crtg 15A 600V 2 DE EE ta Des 010 117 TUBING stl 625 OD x 156 wall x 2 625 lg gedanke Seca 4 AE diera TET s 027 096 TERMINAL ASSEMBLY pri 3ph dual voltage includes 1 Ws erede cet RE 038 974 TERMINAL BOARD pri 1 KT EE 601 836 _ NUT brs hex 250 20 jam bn 80 ER E E 010915 WASHER flat brs 250 ID x 625 OD x 031thk 15 EE 038890 STUD pri bd brs 250 20 x 2 125 18 eege 038 994 LINK jumper pri 2 2 NEE ee ee ne vice 6 EE TEN 038 620 LINK jumper term blk 30A 2 E E 038622 BLOCK term 30A BP 2 TR EE eet 601838 NUT brs hex 375 16 jam Avy 9 EE EE RI N 010910 WASHER flat stl SAE 375 8 GA EE EE 602 213
36. D pur ds 204 360 LIGHT ind white lens includes 1 e vus PL1 027 633 BULB incand bayonet base 8V 1 REPRE 204361 LENS light ind white 1 n BE Start 011 033 PUSH BUTTON operator black 1 9 Start 011 035 CONTACT BLOCK NO PB 1 MO us Stop 011036 CONTACT BLOCK NC PB 1 zd eem Stop 011 034 PUSH BUTTON operator red 1 AE E 016 585 2 COVER dUSt d ere Se NE ee Ge bo eM 1 AS vcard RC2 604 176 RECEPTACLE str dx grd 2P3W 15A 125V 1 A RE 073690 PLUG str grd armd 2P3W 15A 125V P 8 S 5266DF 14 CB1 083 432 SUPPLEMENTARY PROTECTOR man reset 1P 10A 250V 1 OE N EA 026 758 BOOT circuit breaker 1 IG c 038 805 COVER rcpt weatherproof duplex 1 Tf eid RE 004 450 BOOT PB red A rand ux RE re CEA EA ia 1 since 004451 BOOT PB black 1 O A dun ant NAMEPLATE order by model and serial number 1 epe es marne 085 382 LABEL component location 1 1 Hardware is common and not available unless listed 5 2 6 Includes I
37. High Freq Pure Tungsten Green Band 010 Up to 15 Up to 15 Up to 10 020 5 20 5 20 10 20 040 15 80 10 60 20 30 1 16 70 150 10 20 50 100 30 80 3 32 125 225 15 30 100 160 60 130 1 8 225 360 25 40 150 210 100 180 5 32 360 450 40 55 200 275 160 240 3 16 450 720 55 80 250 350 190 300 1 4 720 950 80 125 325 450 250 400 2 Thorium Alloyed Tungsten Red Band 010 Up to 25 Up to 20 Up to 15 020 15 40 15 35 5 20 040 25 85 20 80 20 60 1 16 50 160 10 20 50 150 60 120 3 32 135 235 15 30 130 250 100 180 1 8 250 400 25 40 225 360 160 250 5 32 400 500 40 55 300 450 200 320 3 16 500 750 55 80 400 500 290 390 1 4 750 1000 80 125 600 800 340 525 Zirconium Alloyed Tung sten Brown Band 010 Up to 20 Up to 15 020 gt 15 35 5 20 040 20 80 20 60 1 16 50 150 60 120 3 32 130 250 100 180 1 8 225 360 160 250 5 32 300 450 200 320 3 16 400 550 290 390 1 4 600 800 340 525 4 Typical argon shielding gas flow rates are 15 to 35 cfh cubic feet per hour Not Recommended The figures listed are intended as a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers OM 218 Page 28 8 2 Preparing Tungsten For AC Or DC Electrode Positive DCEP Welding 1 Tungsten Electrode 2 Balled End A Understand and follow 1 safety
38. Terminal Lug Use lugs of proper amperage capacity and hole size for connect ing to work clamp electrode holder and weld output terminals 3 Insulated Electrode Holder Install according to manufacturer s instructions 4 Work Clamp Install onto work cable Tools Needed sb6 1 5 94 Ref ST 144 570 A Ref S 0653 OM 218 Page 12 4 4 Weld Cable Size Total Cable Copper Length In Weld Circuit Not Exceeding 50 ft Or Less 100 ft 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 15m 30m 45 m 60 m 70 m 90 m 105m 120m Welding Amperes 10 Thru 100 Duty Cycle Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere Contact your distributor for the mm equivalent weld cable sizes S 0008 C OM 218 Page 13 4 5 Connecting Weld Output Cables Her Do not place anything between weid cable terminal L and copper bar Tools Needed SLP 3 4 in 19 mm 803 778 B Correct Installation Incorrect Installation A Turn off power before connecting to 1 Weld Output Terminal minal Slide weld cable terminal onto weld weld output terminals 2 Supplied Weld Output Terminal Nut output terminal and secure with nut so that weld cable terminal is tight against copper A Failure to pro
39. V AC N OVERLOAD 10A BREAKER an gt CLOSED Colo OPEN Lo 1 ST 144 570 A Ref ST 174 143 Ref SC 085 382 OM 218 Page 22 B Control Fuses F3 And F4 Turn Off polyweld system and dis A Turn Off polyweld system and dis connect input power connect input power before inspect ing maintaining or servicing 1 Input Terminal Board 2 Fuses F3 And F4 Location 3 Fuse F3 Or F4 See Parts List For Rating 4 Fuse Holder Check F3 or F4 and replace if needed Use proper tool when re moving fuse Close rear access door Tools Needed j C EO 3 8 in Ref ST 144 569 B Ref ST 146 126 C C Module Fuse Links F11 And F12 Through F81 And F82 ar A Turn Off polyweld system and discon Turn Off polyweld system and dis nect input power before inspecting connect input power maintaining or servicing 1 Fuse Links Odd Number Modules 2 Fuse Links Even Number Modules Each of the eight modules is pro tected from overload by a pair of link type fuses FX1 and FX2 OC represents the number of the appli cable module 1 8 If one fuse link for a module opens low weld output is available at the applicable mod ule If both fuse links open no weld output is available at the affected module To replace fuse s proceed as follows Remove upper rear panel Check fuse s and replace if nec essary Reinstall upper rear panel
40. VENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEOUENTIAL 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 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 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 1 05 Owner s Record Please complete and retain with your personal records Mode
41. ade installation and operation quick business and easy With Miller you can count on years NII 00012000 of reliable service with proper maintenance And if for 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 the U S A ta be registered to 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 Mill mer Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 141 SymbollUsage ans ah ah en nn EET Bada HA ed a E TOREM 1 1 2 Arc Welding Hazards 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards i vaca vor gan Pew
42. ainers 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 partition 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 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 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers hi
43. ctice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 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 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body Boo m Keep welding 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 Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION som _3 05 A Avertissement se prot ger et prot ger
44. e cables of same size and length from Negative terminals to a suitable connection point con necting to a single electrode holder cable For Electrode Positive Reverse Polarity DCEP connect jumper link across Negative terminal and Frame Connection terminal for each paralleled module and con nect separate cables of same size and length from Positive termi nals to a suitable connection point connecting to a single electrode holder cable ST 085 152 D OM 218 Page 16 4 7 Remote Amperage Control Receptacle REMOTE AMPERAGE CONTROL 1 Remote Amperage Control Receptacles RCX1 CN Represents The Number Of The Applicable Module 1 8 The twistlock receptacle in each module provides a connection point for an optional remote amperage control To connect to one of these receptacles insert plug from re mote amperage control and turn clockwise ST 144 570 A Ref ST 174 143 EP Tools Needed pu O 3 8 in SK A Turn Off polyweld system and disconnect input power before making contactor control connections Whenever the Remote Contactor switch is closed with Power switch On button pressed input power is applied to all modules Terminal strip 1T provides a con nection point for connecting a nor mally open momentary contact switch for remote contactor control To connect a remote contactor control proceed as follows 1 Terminal
45. e eier hand mer dans la Section 2 5 Lire et e Ne pas enrouler les c bles autour du corps e USA Pa 3 g e Sila pi ce soud e doit tre mise la terre le faire directement avec un A Seul un personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil is e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre A Pendant le fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine i n n x sonnes notamment les enfants de l appareil e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide doubl e UNE DECHARGE ELECTRIQUE peut e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le 9 entrainer la mort champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut RE SP e e Porter un harnais de s curit si l on doit travailler au us du sol provoquer des accidents mortels ou des br lures a Se r r js t S l ai un Se s Ge x nt nn i xn graves Le circuit de l lectrode et de la pi ce est hey el que ous ies PANNEAUX et COUYSTEISS sant soirestement en sous tension lorsque le courant est d livr a la place p sortie Le circuit d alimentation et les circuits internes de la machine e Fixer le cable de retour de fa on obtenir un bon co
46. ectrode holder cable to Positive terminal For Electrode Negative Straight Polarity DCEN reverse cable connections Common Work Connections 6 Common Work Connection Terminal 7 Common Work Cable See Table 3 1 for proper cable size 8 Frame Connection Terminal 9 Jumper Link For Electrode Negative Straight Polarity DCEN connect jumper link across Positive terminal and Frame Connection terminal and connect electrode holder to Nega tive terminal For Electrode Positive Reverse Polarity DCEP connect jumper link across Negative terminal and Frame Connection terminal and connect electrode holder to Positive terminal ST 144 568 C Table 3 1 Common Work Cable Size Common Work Cable Sizes At Main Transformer Rated Welding Current Cable Length Cable Size 50 Feet 2 No 3 0 100 Feet 2 No 4 0 150 Feet 3 No 3 0 200 Feet 3 No 4 0 OM 218 Page 15 B Parallel Module Connections A Be i Separate Work Ze Connections Common Work Connections Tools Needed IZ 1 1 4 in A READ SAFETY BLOCKS at start of Section 4 6 before proceeding UNDERSIZED WELDING CABLES can cause fire Use single cables of adequate capacity to carry the total combined am perage of the paralleled modules see Section 4 4 Securely cover common connections with proper insulating materials Set the Amperage Adjustment controls on all paralleled modules to provide
47. enerators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified DS 2Wire Feeder Motor Driven Guns w exception of Spoolmate Spoolguns Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HFUnits Grids Maxstar 85 140 Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma 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 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets 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
48. ent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque rester danger eX D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusementavec des protections homologu es Ne pas souder dans un endroit o des tincelles peuvent tomber sur des substances inflammables Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t 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 pa r s correctement conform ment AWS F4 1 voir les normes de s curit Brancher le 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 provoquant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisati
49. g lifting forks extend forks beyond opposite side of unit 3 Rating Label Movement Use rating label to determine input power needs 4 Line Disconnect Device Locate unit near correct input pow er supply OR Location And Airflow 18 in 460 mm Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 18 in Y 460 mm INPUT SERIAL NO Do not block airflow 3 ia to bottom of unit VOLTS AMPERES KW PHASE HERTZ ssb9 1 5 94 ST 801 180 ST 144 567 A OM 218 Page 11 4 2 Dimensions Weights And Base Mounting Hole Layout NOTE F Overall dimensions A B and C include lifting eye handles hardware etc Front Dimensions 77 1 4 in 1943 mm 72 in 1829 mm 40 in 1016 mm 52 1 2 in 1334 mm 3 4 in 19 mm 38 1 2 in 978 mm 26 1 4 in 667 mm IIO nim olol w gt 36 in 914 mm Gas 1 2 in Dia 13 mm Dia 4 Holes Weight Ref ST 144 567 A 4050 lb 1837 kg 4 3 Selecting And Preparing Weld Output Cables 10 ft 3 m For Example Total Cable Length In Weld Circuit 20 ft 6 m 1 Weld Output Cable Determinetotal cable length in weld circuit and maximum welding am peres Use Section 4 4 to select proper cable size Use shortest cables possible Do not use damaged cables 2
50. ge onduleur quand on a coup l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereuse pour la sant e D autres consignes de s curit sont n cessaires dans les conditions e Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s sur des structures m talliques telles que e A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de Sols grilles ou chafaudages en position coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou Sila ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un p
51. gh shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby A FLYING METAL 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 OM 218 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed e e Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding 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
52. is unit FALLING UNIT can cause injury 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 If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit nn LU OVERUSE can cause OVERHEATING e Allowcooling period follow rated duty cycle ee e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit ee STATIC ESD can damage PC boards y e Put on grounded wrist strap BEFORE handling ASS boards or parts So e Use proper static proof bags and boxes to store move or ship PC boards amp MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury 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 E 3 1 4 California Proposition 65 Warnings A 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 Safety Code Section 25249 5 et seg gt Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California
53. l Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip n N 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 Safety 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 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 amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com C Miller
54. 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 curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que Valimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser 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 SUR ar nn L EMPLOI EXCESSIF peut CHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement respecter 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 nn nn ee amp LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e
55. lt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone 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 Properly install and ground this equipment according to its Owner s Manual and national state and local codes 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 When making input connections attach proper grounding conduc tor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill AEN This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards Turn off all equipment when not in use Do not use worn damaged 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 Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do nat touch electrode holders connected to two
56. n Select type and size of overcurrent protection using Section 4 11 fused disconnect switch shown Close and secure door on line disconnect de vice Remove lockout tagout device and place switch in the On position OM 218 Page 19 4 11 Electrical Service Guide Input Voltage 220 230 380 440 460 575 Input Amperes At Rated Output 178 170 103 89 85 68 Max Recommended Standard Fuse Rating In Amperes Time Delay 2 200 200 125 110 100 80 Normal Operating 3 250 250 150 125 125 100 Min Input Conductor Size In AWG 3 0 2 0 2 3 3 4 230 214 349 389 424 554 Max Recommended Input Conductor Length In Feet Meters 70 65 106 118 129 169 Min Grounding Conductor Size In AWG 4 4 6 6 6 8 Reference 2005 National Electrical Code NEC 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp 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 SECTION 5 OPERATION BOE IS ARE E A o
57. n 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 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 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 OM 218 Page 1 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 the weld e Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes 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 mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed cont
58. nect green or green yellow conductor to supply grounding termi nal first and never to a line terminal See rating label on unit and check input volt age available at site 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 11 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Con nections 2 Strain Relief Customer Supplied Route conductors cord through strain relief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Connect green or green yellow grounding conductor to welding power source grounding terminal first 5 Welding Power Source Line Terminals 6 Input Conductors L1 U L2 V And L3 W Connect input conductors L1 U L2 V and L3 W to welding power source line terminals Close and secure access door on welding power source ssb2 4 1 94 Ref ST 144 569 B Disconnect Device Input Power Connec tions 7 Disconnect Device switch shown in OFF position 8 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding ter minal first 9 Disconnect Device Line Terminals Connect input conductors L1 U L2 V And L3 W to disconnect device line terminals 10 Overcurrent Protectio
59. ntact metal metal sont galement sous tension lorsque l alimentation est sur Marche avec la pi ce souder ou la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique la terre de mani re incorrecte ou impropre constitue un danger e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse e Ne pas toucher aux pi ces lectriques sous tension e 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 avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip une m me borne de sortie de soudage Il reste une TENSION DC NON N GLIGEABLE dans les sources de souda
60. odule should not exceed the rated duty cycle of the main transformer For example the polyweld system can be safely operated at a load of 1000 amperes at 60 percent duty cycle This value could be obtained by operating five modules at a load of 200 amperes at 60 percent duty cycle or by operating eight modules at a load of 125 amperes at 60 percent duty cycle Overheating Thermostat TP1 protects the polyweld system If main transformer T1 gets too hot TP1 opens and weld output stops The stabilizer in each of the eight modules is pro tected from overheating by thermostat TPX1 X represents the number of the applicable module 1 8 If overheating of a stabilizer occurs the associated ther mostat opens reducing weld output to a minimum that cannot be regulated The fans keep running to cool the stabilizer Wait several minutes before trying to weld T x a gt cB minutes When overheated thermostat Let fans run for Start welding opens output decreases or stops 15 minutes and cooling fans keep running ssb10 1 1 94 SB 002 919 C ST 144 567 A OM 218 Page 10 SECTION 4 INSTALLATION 4 1 Selecting A Location And Moving Polyweld System UA um b 1 Lifting Eye 7 Ar 2 Lifting Forks Use lifting eye or lifting forks to move unit A Disconnect input power conductors from deenergized supply BEFORE moving polyweld system If usin
61. olt Ampere Curves DC VOLTS EACH MODULE MIN 300 400 DC AMPERES The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of each module Curves of other set tings fall shown between the curves ssb1 1 10 91 SB 083 110 C OM 218 Page 9 3 3 Duty Cycle And Overheating Y uj For Each Module And Total System Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating If unit overheats thermostat s 2000 opens output stops and cooling 1600 fan runs Wait fifteen minutes for 1200 unit to cool Reduce amperage or 1200 duty cycle before welding g 1000 A Exceeding duty cycle can m Li 800 A I OE OUTPUT damage unit and void 2 300 warranty C 245 E 200 TL EACH MODULE OUTPUT 155A 10096 100 10 20 20 40 50 60 70 80 90 100 60 Duty Cycle At 200 Amperes 96 DUTY CYCLE Ls gt 6 Minutes Welding 4 Minutes Resting For Main Transformer The main transformer of the polyweld system has dual duty cycle ratings each for a specific amperage output range If the unit is operated in the 800 ampere range the unit is rated at 100 duty cycle This means the polyweld system can be oper ated at 800 amperes continuously When the unit is operated in the 1600 ampere range it is rated at 25 duty cycle The sum of the outputs of each m
62. on enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur proximit DES PARTICULES VOLANTES peuvent blesser 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 Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 218 Page 6 distance e Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter 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
63. oste souder AC tension vide r duite Dans la plupart des rev tements les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d oxyg ne provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente aucun danger e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situ s proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de puiv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute SES 3 d el ment toxiques et irritants e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer e Ne pas souder des m taux munis d un rev tement tels que l acier gal
64. perly connect weld 3 Weld Cable Terminal bar Do not place anything between weld cables may cause excessive heat 4 Copper Bar cable terminal and copper bar Make and start a fire or damage your ma sure that the surfaces of the weld cable chine Remove supplied nut from weld output ter terminal and copper bar are clean 4 6 Connecting To Weld Output Terminals 4 WARNING ELECTRIC SHOCK can kill ARCING can burn skin or damage electrical connections e Do not touch live electrical parts e Turn Off polyweld system by pressing Power Off push button before making any weld output connections e Do not connect welding output of different polarities to the same structure e See ANSI 249 1 and OSHA Title 29 Chapter XVII Part 1910 Subpart Q addresses at beginning of manual o When Positive or Negative weld output terminal is jumper linked to the Frame Connection terminal and the work cable is con nected to the Common Work Connection stud on the machine base do not connect a cable between the remaining weld output terminal and the work e Remove jumper link from any module where work and electrode connections are made directly to the Positive and Negative output studs e Do not handle or come in contact with two live electrodes at the same time e Connect all paralleled modules for the same polarity EE ELECTRIC SHOCK can kill TWO TIMES NORMAL OPEN CIRCUIT VOLTS exist between elec trode holders of opposite polarity
65. 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 associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder 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 A FIRE OR EXPLOSION hazard 4 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 th
66. rchaser 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 provide 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 date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated J ntellitig Maxstar 150 Engine Driven Welding G
67. rn eh 4 1 6 EMF Information iii RE ee EO BL Oda ee E ee nent 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 1 Symboles utilises Cta sd ds nr lea thee 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 7 2 5 Principales normes de s curit 8 2 6 Information EMP RE N ire na pne py ce Ne d Na el 8 SECTION 3 SPECIFICATIONS 42 22 er erase A 9 3 1 Specifications ssec eret e ep e ae RE I be Gabe Sach REG d 9 3 2 Volt Ampere CUrVes ANERER E ER ENEE EE SE a 9 3 3 Duty Cycle And Overheating Ae en A 10 SECTION 4 INSTALLATION 2 42 23 dE Ne a das 11 4 1 Selecting A Location And Moving Polyweld System 11 4 2 Dimensions Weights And Base Mounting Hole Layout 12 4 3 Selecting And Preparing Weld Output Cables 12 4 4 Weld Cable Size obe A RE A A A 13 4 5 Connecting Weld Output Cales 14 4 6 Connecting To Weld Output Terminals 14 4 7 Remote Amperage Control Receptacle
68. robl mes de procr ation Se laver les mains apr s manipulation OM 218 Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping 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 Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 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 souda ge causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500
69. tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes PC y amp DES ORGANES MOBILES peuvent provoquer 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 blessures e Ne pas appuyer sur la g chette avant d en avoir re u l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geant le fil de soudage PAL DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels S que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettreles portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences
70. tem 7 Ss N j Y ad 1 N 4 ES v jo yee fl Y 11 12 Zu f Ze a Ds ne N N NS gt A 19 20 13 155 303 A Figure 10 4 Panel Front Lower w Components When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts 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 218 Page 37 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 C Miller Effective January 1 2005 Equipment with a serial number preface of LF 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 pu
71. 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 Laccumulation de preuves suivant le jugement du comit ma pas d montr que l exposition aux champs magn tiques et champs lec triques 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 tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes OM 218 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 telephone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 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 1 Battery March Park 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
72. ure 10 1 Main Assembly Section A gt FM1 2 032605 MOTOR cap perm SP 1 4hp 230VAC 1625RPM 2 bg OP ae AA 071763 FRAME mtg fan motor 2 RE EN 014544 CHAMBER plenum 2 o E O teats rt 147558 BLADE fan 20 in 3wg 21deg 500 bore CCW 2 Sei eRe terrane tae tts 087 125 TEE 2 W 086 677 COLUMN corner LH front A RH rear 2 ME OS 14415890 BASE is ES cash EEN 1 E ACAD 086 678 COLUMN corner RH front LH rear 2 EE ns ea 032 473 GASKET lift eye 1 ENT 032 474 COVER pop 1 Al ax MA Z 099 480 AMPLIFIER 8 STABILIZER mag includes 8 T ia 084 932 STABILIZER includes 1 EE et TP11 200936 THERMOSTAT NC 1 215 SR11 210 352 RECTIFIER ASSEMBLY si diode 1 AG a a 086 679 PANEL rear upper 2 AAN 087 178 PANEL rear lower 1 Oia ata 102207 PLATE adapter power cord 1 O 087 124 FRAME mtg module center 2 EE DE EE 020 279 CLAMP stl cush 750dia x 281mtg hole

Miller Electric MARK VIII-2 User's Manual

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