Mamiya Econotig User's Manual
Contents
1. Ee aint 21 SECTION 10 PARTS LIST RUE EH PED E SR NI UE 22 OPTIONS AND ACCESSORIES WARRANTY Notes SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 4 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 pum 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 shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circ2. 1 1 271555005 LIGHT indicator eta Gd Wa ee ee a 1 Pan OO 148 956 HANDLE switch 1 ra EE PL2 157957 LIGHT ind blu lens 28V snap mtg 1 40 S3 155013 SWITCH rocker SPST 10A 250VAC 1 ee ares NAMEPLATE order by model serial number 1 303 23 Item Dia Part No Mkgs No Description Quantity Figure Figure 10 1 Main Assembly Continued 42 PL1 157958 LIGHT ind wht lens 28 1 1554227 PANEL front Rie EE 1 adu S2 154896 SWITCH polarity includes 1 S4 224276 SWITCH lim 11A 125V roller lever actr 1 AO irs Sec 177 359 CABLE work assembly includes 1 a sete 010368 CLAMP work 200A 1 sts AO 026 843 INSULATOR vinyl 2 E Dd Den 198 317 HOSE gas 12 ftrubber 11 192 121 REGULATOR FLOWMETER 10 50 cfh 2 1 RE 176 840 ELECTRODE HOLDER CABLE includes
3. 1 RE 134 460 CONNECTOR twlk insul male 1 em 185 759 LABEL warning electric shock amp input power 1 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 303 Page 24 Notes 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 2 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 o
4. of Front Panel Control APPROXIMATE OUTPUT AMPERAGE VS DIAL X S Ge Wee DO SWITCH UNDER LOAD 80 AO STICK 0 A 100 In Example Range DC Percentage of Range 50 Select weld process Select range and polarity Select percentage Weld Amperage 33 A DC 6 3 Example of Remote Amperage Control DC 18 50A 2 ARC STARTER ACTIVE IN TIG MODE AO STICK Select weld process Ga or Connect remote control A DO NOT SWITCH UNDER LOAD ei ER 40 20 80 WARNING ELECTRIC SHOCK CAN KILL desc sHocK can A 100 IF MOVEMENT IS CONFINED OR IF THERE IS A DANGER OF FALLING USE AC OUTPUT ONLY IF REQUIRED FOR THE WELDING PROCESS Select range and polarity Select percentage GTAW Welding Amperage Range AC Low AC High DC 20 50A 60 165 30 165 In Example Range DCEN Percentage of Range 50 Remote weld amperage 30 98 A DC 50 of 30 165 DC OM 303 Page 16 6 4 Process and Material Thickness Guide Label Guideline For Welding Process And Output For Material Material Thickness Material And 22ga 20ga 18ga 16ga 14ga 12 ga 11 ga 10 ga 6 ga 2 ga Weld Output 0 033 in 0 036 in 0 048 in 0 06in 0 07 D
5. Miami FL 33126 OSHA Safety and Health Standards 29 CFR 1910 from U S Gov Printing Office P O Box 371954 Pittsburgh PA 15250 7954 WELDING can cause fire or explosion Do not weld near flammable material Watch for fire keep extinguisher nearby Do not locate unit over combustible surfaces e Do not weld on closed containers ARC RAYS can burn eyes and skin NOISE can damage hearing e Wear welding helmet with correct filter e Wear correct eye ear and body protection SOUDAGE A LARC peut etre hasardeux eLire le manuel d instructions avant utilisation eNe pas installer sur une surface combustible eLes fils de soudage et pieces conductrices peuvent etre a la tension de soudage 203 990 OM 303 Page 9 3 2 Symbols And Definitions Tig Welding S Remote Foot Hand Control Stick Welding High Temperature Output Alternating Current Direct Current On d Electrode Do Not Switch Electrode Positive EN Negative i nder Load 67 Voltage Input A Amperes O Off Bi Electrode gt Gas Out asd ontrol A PERENNEM Work Remote V Volts Rated No Load U Conventional Load X Duty Maximum Effective 0 Voltage Average 2 Voltage y Supply Current Rated Maximum Rated Welding P Degree Of e De Imax Supply Current 2 Current Protection D Les Power Source U Primary Voltag
6. OM 303 155 795T i May 2005 Miller Ed Gas Tungsten Arc A TIG Welding Shielded Metal Arc Stick Welding Description Arc Welding Power Source A 53 A Econotig C Visit our website at www MillerWelds com EI OWNER S MANUAL 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 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 made installation and operation quick business and easy With Miller you can count on years 90 00012000 of reliable service wit
7. Miller
8. ST 158 075 5 2 Typical Stick Connections Turn Off power before mak ing connections 1 Electrode Holder 2 Work Clamp Connect to receptacle as shown Per ST 157 858 A OM 303 Page 12 5 3 Typical TIG Connections Per Tools Needed 5 8 1 1 8 Turn Off power before mak ing connections 1 Remote Control 2 Torch Connect to receptacles as shown 3 Work Clamp 4 Cylinder Chain or secure cylinder to running gear wall or other stationary support 5 Cylinder Valve Open valve slightly so gas flow blows dirt from valve Close valve 6 Regulator Flow Gauge Install so face is vertical Flow Adjust Typical flow rate is 20 cfh cubic feet per hour 9 4 L min Ref ST 157 858 A OM 303 Page 13 5 4 Electrical Service Guide S 0092J CS For 230 V models with wall receptacle 100 duty cycle used to calculate data below 20 duty cycle used for all other models Input Voltage 200 230 380 415 460 Input Amperes At Rated Output 60 52 39 36 338 Max Recommended Standard Fuse Rating In Amperes Time Delay 70 60 45 40 30 Normal Operating 90 80 60 50 40 Min Input Conductor Size In AWG 4 10 6 12 12 14 Max Recommended Input Conductor Length In Feet Meters be a 151 46 181 55 85 26 Min Grounding Conductor Size In AWG 4 10 8 12 12 14 Reference 2005 National Electrical Cod
9. 1 DC ad bee T1 193877 TRANSFORMER pwr main 415V includes 1 EE 1 2 176170 THERMOSTAT NC 2 rite pote etes 083 147 GROMMET screw 8 10 panel hole 312sq 500 high 4 RCE RES Wiz 188009 CONTACT OR ges dann ties dae REP ans ate ah ies 1 QA EE 2 155501 Ae A e dns 1 25 GT 2 55290 7 CAPAO TO R WEE EE 1 zi 26 T2 188 061 TRANSFORMER impulse HV 1 pas P aou Z2 155499 TRANSFORMER blocking includes 1 at gt vase 159 102 PLATE mtg block transformer 1 sans s s ratibus vate 155288 blocking 1 ARTE 124511 SWITCH tgl DPST 40A 600VAC 1 165987 BASE eu EAA 1 32 Elec 186 092 RECEPTACLE 1 R1 035 897 POTENTIOMETER C sltd 1T 2W 1 1 EOD MEE 134 900 STRAIN RELIEF cable flex 270 480 cable 1 35 143976 CONNECTOR w SOCKETS 1 097 924 KNOB pointer
10. 5 Workpiece 6 Work Table OM 303 Page 20 9 3 Correct Installation Ground all metal ob jects and all wiring in welding zone using 12 AWG wire ES 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 and 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 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 spec ifications Ref S 0695 Ref S 0695 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
11. Unit overheated Allow unit to cool see Section 4 3 Fan not operating weld output available Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor OM 303 Page 18 SECTION 8 ELECTRICAL DIAGRAMS 3004193130 N N 00000 00000 Z9 21 Z gc Ee lt 1 0128 lt 6 994 69 Sito AA ge 32 95 lt 01 198 GG lt B 8 gt lt L 198 gt lt lt lt H gg amp 10d 194 RCI 0197d 0194 9919 93 9919 9935 9714 7924 9 1d 24 c9 1d c24 193 123 13d SB 154 141 C Figure 8 1 Circuit Diagram OM 303 Page 19 SECTION 9 HIGH FREQUENCY 9 1 Welding Processes Requiring High Frequency Work TIG 1 High Frequency Voltage Helps arc jump air gap between torch and workpiece and or stabilize the arc high freg1 11 96 5 0693 9 2 Incorrect Installation Sources of Direct High Frequency 11 12 Sources of Conduction of High 15 5 0694 Sources of Reradiation of High Radiation Frequency Frequency 1 High Frequency Source welding power 7 Input Power Cable 10 Ungrounded Metal Objects source with built in HF or separate HF 8 Line Disconnect Device 11 Lighting 2 Cables 9 Input Supply Wiring 12 Wiring 3 Torch 13 Water Pipes and Fixtures 4 Work Clamp 14 External Phone and Power Lines
12. DC OCV Weight TIG 150 A at 15 VDC 50 165 20 50 30 160 GTAW 150 at 15 VAC 380 V 39 2 0 14 8 6 7 H 18 in 457 mm 140 Ib Stick 180Aat25 VDC 35 165 20 50 25 180 78 415V 36A 1 5 064 0 3 W 13in 830mm 4 9 SMAW 150 A at 25 VAC D 251 2 in 648 mm While idling 4 3 Duty Cycle Chart Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating Exceeding duty cycle damage unit and void warranty 20 Duty Cycle at 150 AC DC SMAW 20 Duty Cycle at 130 DC or 150 A AC 2 2 Minutes 8 Minutes 15 20 25 30 40 50 60 70 80 90 100 i i X DUTY CYCLE Welding Resting ST 157 648 A 4 4 Volt Ampere Curves Volt ampere curves show minimum and maximum voltage and amper age output capabilities of welding power source Curves of other set tings fall between curves shown 80 80 LOW RANGE 70 60 B HIGH RANGE 60 P 50 d 50 Q 40 Q 40 Q Q 30 20 20 10 10 0 1 1 0 1 A 1 d 0 50 100 150 200 250 500 0 50 100 150 200 250 300 5 DC AMPERES ssb1 1 10 91 ST 157 625 B ST 157 626 B OM 303 Page 11 SECTION 5 INSTALLATION 5 1 Selecting a Location Position unit so air can circulate For information about sources of high frequency see Section 9 For carts and caster kits see back of book or contact your distributor
13. Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated J ntellitig Maxstar 150 Engine Driven Welding Generators 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 fai
14. SOUDAGE peut causer un incen die ou une explosion Le soudage effectu sur des r cipients ferm s tels que des r servoirs des f ts ou des conduites peut causer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles les pi ces chaudes et les quipements chauds peuvent causer des incendies et des br lures Le contact accidentel de l lectrode avec tout objet m tallique peut causer des tincelles une explosion un surchauf fement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et prot ger les tiers de la projection d tincelles et de m tal chaud e Ne pas souder un endroit o des tincelles peuvent tomber sur des substances inflammables e Placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections agr es e Des tincelles et des mati res en fusion peuvent facilement passer m me par des fissures et des ouvertures de petites dimensions e Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit e Le soudage effectu sur un plafond un plancher une paroi ou une cloison peut d clencher un incendie de l autre c t Ne pas souder des r cipients ferm s tels que des r servoirs des f ts ou des conduites moins qu ils n aient t pr par s
15. available but may vary from province to province miller_warr 1 05 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 N N aW 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
16. conform ment l AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter que le courant ne circule sur une longue distance par des chemins inconnus et ne cause des risques d lectrocution et d in cendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil au raz du tube contact e Porter des v tements de protection exempts d huile tels que des gants en cuir une chemise en tissu pais des pantalons sans revers des chaussures montantes et un masque e Avant de souder retirer tout produit combustible de ses poches tel qu un briquet au butane ou des allumettes LES PARTICULES PROJET ES peu e es vent blesser les yeux e Le soudage le burinage le passage de la pi ce la brosse m tallique et le meulage provoquent l mission d tincelles et de particules m talli ques Pendant leur refroidissement les soudures risquent de projeter du laitier des lunettes de s curit crans lat raux agr s m me sous le masque de soudage OM 303 Page 6 a LES ACCUMULATIONS DE GAZ peu vent causer des blessures ou m me la mort e Couper l alimentation en gaz protecteur en cas de non utilisation Veiller toujours bien ventiler les espaces confin s ou porter un respira teur a adduction d ai
17. pour lever l appareil e Sion utilise un chariot l vateur pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t op pos de l appareil an T Hi L EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L QUIPEMENT T e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de reprendre le soudage Ne pas obstruer les orifices ou filtrer l alimentation en air du poste ee LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s gt amp ASS e Mettre un bracelet antistatique AVANT de mani puler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprim s LES PI CES MOBILES peuvent cau ser des blessures e Se tenir l cart des pi ces mobiles e Se tenir l cart des points de coincement tels que les d vidoirs LES FILS DE SOUDAGE peuvent cau ser des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi vers d autres personnes ou vers toute pi ce m canique en en gageant le fil de soudage PAL x LES ORGANES MOBILES peuvent causer des blessures CA e Se tenir l cart des organes mobiles comme les ventilateurs e Maintenir ferm s et bien fix s les portes pa
18. soudage sur une bouteille de gaz e jamais mettre une lectrode de soudage en contact avec une bou teille de gaz e Ne jamais souder une bouteille contenant du gaz sous pression elle risquerait d exploser e N utiliser que les bouteilles de gaz protecteur r gulateurs tuyaux et raccords ad quats pour l application envisag e les maintenir en bon tat ainsi que les pi ces connexes e D tourner la t te lorsqu on ouvre la soupape d une bouteille e Laisser le capuchon protecteur sur la soupape sauf en cas d utilisa tion ou de branchement de la bouteille e Lire et suivre les instructions concernant les bouteilles de gaz compri m les quipements associ s et les publications P 1 de la CGA mentionn es dans les normes de s curit 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil Risque D INCENDIE OU D EXPLO SION Ne pas placer l appareil sur une surface inflam mable ni au dessus ou proximit d elle Ne pas installer l appareil proximit de produits inflammables Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e N utiliser que l anneau de levage pour lever l ap pareil NE PAS utiliser le chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin de capacit ad quate
19. Overhead Door Track Ground the track OM 303 Page 21 SECTION 10 PARTS LIST Hardware is common not available unless listed ST 801 399 D Figure 10 1 Main Assembly OM 303 Page 22 No Mkgs No Description Quantity Figure 10 1 Main Assembly cu 154335 BEZEL SiL aw SY Race ate EA 1 EE NO 203 990 LABEL warning general precautionary 1 D PORN ET RS 165 9867 WRAPPER wis een es cU bd dace X CA gaa 1 4 PCT 183876 CIRCUIT CARD arc start control 200 230 460V models includes 1 4 PCT 186172 CIRCUIT CARD arc start control 380 415V models includes 1 P F1 012658 FUSE mintr gl slo blo 2A 1 TON PLG1 6 130 203 CONNECTOR amp SOCKETS 2 20 134 201 STAND OFF SUPPORT PC 312 375 4 zx Ordres us 155404 BRACKET mtg components 1 wb EK 603 106 HOSE nprn brd No 1 order by ft 3ft EIA TEE 089 120 CLAMP hose 430 515 clp 2 9 GS1 216396 VALVE 24VAC 2 way custom port 1 8 orf 1 137 761 NU
20. 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 303 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 W
21. Section 20 230 Volt Models Units come equipped with input power cord and plug Wall receptacle is cus tomer supplied To install select type and size input and grounding conduc tors using Section 5 4 Conductor rating must comply with national state and local electrical codes Install and connect grounding conduc tor and input conductors in conduit or equivalent between wall receptacle and deenergized line disconnect device All Other Models Units come equipped with input power cord for installation into line disconnect device Select type and size overcur rent protection using Section 5 4 ST 161 454 A OM 303 Page 14 SECTION 6 OPERATION 6 1 Controls Iw M ARC STARTER ACTIVE IN TIG MODE b e S Ze STICK GI OUTPUT ON CONTACTOR WELD PROCESS HIGH TEMP SHUTDOWN DO SWITCH UNDER LOAD INING ELECTRIC SHOCK CAN KILL T DAMP AREAS FOR THE WELDING PROCESS RANGYSPOLARITY SWITCH AMPERAGE RATED output DC AC AC DC STICK STICK TIG 25 1 VOLTS 25 5 5 130 150 150 DUTY CYCLE 20 20 20 78 75 78 1 Weld Process Switch Use switch to select weld process In Stick position down weld output goes On and Off with Power switch GTAW TIG position up remote control device turns on and adjusts weld outp
22. T 750NPT 1 1 27H nyl blk 1 TELE T4571 3 HANDLE dent ian Se ha E E 2 t e outs atus 4155 399 PANEL 168b sca ace ea de te bou e CEU UAE a te a t 1 PUMP 071906 CORD SET 8 10ga 3 c 200 380 460V model 1 13 PLG12 047 721 CORD SET 250V 6 50P 8 10ga 3 c 230V model 1 i erue 605 077 CABLE port 10 3 380 415 460V Model order by ft aft EM 604 102 CONNECTOR clamp cable 1 000 1 more ss 19203175 RECTIFIER ia 1 16 1 2 044482 SUPPRESSOR 1 HAT asd A 150783 BLADE fan 9 in 312 1 PMR FM 188 706 MOTOR fan 230V 1550RPM 312dia shaft 1 9 bugie 203 598 BRACKET mtg fan amp rectifier 1 WEE Zt gen 193871 STABILIZER e 1 Pe sos T1 193869 TRANSFORMER pwr main 200V includes 1 ees T1 193 873 TRANSFORMER pwr main 230V includes 1 ECH REN T1 193874 TRANSFORMER pwr main 460V includes 1 PEE SEES T1 193875 TRANSFORMER pwr main 380V includes
23. d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irri tants e Ne pas souder de m taux munis d un rev tement tels que la t le d acier galvanis e plomb e ou cadmi e moins que le rev tement n ait t enlev dans la zone de soudage que l endroit soit bien venti l et si n cessaire porter un respirateur adduction d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques lorsqu on les soude OM 303 Page 5 LES RAYONS DE L ARC peuvent cau ser des br lures oculaires et cuta n es Le rayonnement de l arc g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges suscep tibles de causer des br lures oculaires et cutan es Des tincelles sont projet es pendant le soudage Porter un masque de soudage muni d un filtre de la nuance ad quate pour se prot ger le visage et les yeux pendant le soudage ou pour re garder voir les normes de s curit ANSI Z49 1 et Z87 1 e Porter des lunettes de s curit crans lat raux sous le masque e Utiliser des crans ou des barri res pour prot ger les tiers de l clat blouissant ou aveuglant de l arc leur demander de ne pas regarder l arc Porter des v tements de protection en mati re durable et ignifuge cuir ou laine et des chaussures de s curit FS LE
24. d une lectrode ou plus d un c ble de masse un m me terminal de sortie subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimentation lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions nonc es la section Entretien avant de toucher les pi ces 2 LES FUM ES LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz dont l inhalation peut tre dangereuse pour la sant e Setenir distance des fum es et ne pas les inhaler e A l int rieur ventiler la zone et ou utiliser un dispositif d aspiration au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur adduction d air agr e Lire les fiches techniques de sant s curit FTSS et les instruc tions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Netravailler dans un espace clos que s il est bien ventil ou porter un respirateur adduction d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent se substituer l air abaisser la teneur en oxyg ne et causer des l sions ou des accidents mortels S assurer que l air est respira ble Ne pas souder proximit d op rations de
25. e NEC including 1 Consult factory for circuit breaker applications 2 Time Delay fuses are UL class RK5 article 630 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 5 5 Connecting Input Power Per Tools Needed When making connections in the line disconnect device connect the Green Or Green Yellow ground conductor first All Other Models GND PE Ke E Lo L2 v Install conductors into a deenergized line disconnect device 230 Volt Models Only e L2 230 VAC 1 Have only qualified persons make this installation Disconnect and lockout tagout input power before connecting input conductors for wall recep tacle or from unit Special installation may be required where gasoline or vola tile liquids are present see Article 511 or CEC
26. e Line Connection H Hertz Jo 1 ose TL Z SECTION 4 INTRODUCTION 4 1 Included with Your Unit E aie LJ 5 Le 5 3 1 12ft 3 7 m Work Cable and Clamp 2 150 Amp TIG Torch with 12 1 2 ft 3 8 m Cord and Flow Through Quick Connect 50 Hz models come with 25 ft 7 6 m TIG Torch 3 Electrode Holder and Quick Connect 4 Gas Hose 5 Regulator Not included with 50 Hz models 6 How To DVD 7 RFC 14 Foot Control with 20 ft 6 m Cord 60 Hz models only 50 Hz models come with RCC 14 fingertip control instead 8 8 ft 2 4 Primary Cord Plug supplied with 230 Volt model only Some assembly is required For options and accessories see back of book or contact your dis tributor OM 303 Page 10 4 2 Specifications A 60 Hertz Models Rated Output at 20 Duty Welding Amperage Range Max Rated Output KVA KW Dimensions Net Cycle AC High ACLow DC OCV Weight TIG 150 A at 15 VDC GTAW 150 A at 15 VAC 50 165 20 50 30 160 200 V 60 A 3 6 12 0 5 4 H 18 in 457 mm 140 Ib ae 78 230V 52A 3 0 0 64 0 3 W 13in 330mm 64 9 eg 460 V 33 A 1 5 D 251 in 648 mm SMAW 150 25 VAC 35 165 20 50 25 130 While idling B 50 Hertz Models Rated Output at 20 Duty Welding Amperage Range Max Rated Output KVA KW Dimensions Net Cycle AC High ACLow
27. 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 nn LU OVERUSE can cause OVERHEATING e Allow cooling 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 gt e Puton grounded wrist strap BEFORE handling ASS boards or parts eo 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 Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do 50 e Do not point gun toward any part of the body other people or any metal when threading welding wire 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 P MOVING PARTS can cause injury Ke
28. ectives A ldentifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc Les symboles ci apr s sont utilis s tout au long du pr sent manuel pour attirer l attention sur les dangers potentiels et les identifier Lorsqu on voit un symbole faire preuve de vigilance et suivre les directives mentionn es afin d viter tout danger Les consignes de s curit nonc es ci apr s ne font que r sumer le contenu des normes de s curit mentionn es la section 2 4 Lire et respecter toutes ces normes installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Pendant l utilisation de l appareil tenir l cart toute personne en particulier les enfants 24 LES D CHARGES LECTRIQUES peuvent tre mortelles Un simple contact avec des pi ces sous tension peut causer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est en fonctionnement Le circuit d entr e et les circuits internes de l appareil sont galement sous tension En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Tout mat riel mal install ou mal mis la terre pr sente un danger e Ne jamais
29. ep away from moving parts such as fans CA 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 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 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 Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible inte
30. est 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 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 2 1 Signification des symboles Signifie Mise en garde Faire preuve de vigilance Cette proc dure pr sente des risques identifi s par les symboles adjacents aux dir
31. h 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 1 121 Symbol sso e qu Vee CP NO Y YU CEDE TE E A 1 1 2 Arc Welding Hazards tenere ate UG ne tes 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 08 3 1 5 Principal Safety Standards 4 1 6 EME Information g
32. in 0 125in O 14 in 0 186 0 25in 0 25 in 0 8 mm 0 9 mm 1 2 mm 1 5 mm 1 8mm 2 5 mm 3 2 mm 3 6 mm 4 8 mm 6 3mm 6 3 mm Steel Or Stainless Steel SMAW A um en lo DCEN 4 70 ELECTRODE GTAW GTAW With DCEP NEGATIVE F F Output Aluminum 2 e 2 fe GTAW U Difficult Recommended 2 e Et AC Not Recommended S 167 338 303 Page 17 SECTION 7 MAINTENANCE AND TROUBLESHOOTING 7 1 Routine Maintenance Per Disconnectpower before maintaining gt Maintain more often during severe conditions 3 Months Replace unreadable labels Clean and tighten weld terminals 22 i LE Repair or replace cracked weld cable Repair or replace cracked gas hose Replace o ring in Electrode Gas Output receptacle if cracked 6 Months Blow out or vacuum inside 7 2 Troubleshooting Trouble Remedy No weld output fan does not run Place line disconnect switch in On position see Section 5 5 Check and replace line fuse s if necessary or reset circuit breaker see Section 5 5 Check for proper input power connections see Section 5 5 No weld output fan on Be sure Range Polarity switch is not set between positions Tighten remote control connection to Remote 14 receptacle Check remote control see remote control Owner s Manual
33. l 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 Equipmentthat 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 tra
34. la National Fire Protection Association Box 9101 1 Battery March Park Quincy 02269 9101 t l phone 617 770 3000 sites Web www nfpa org et www sparky org Safe Handling of Compressed Gases in Cylinders brochure CGA P 1 de la Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Web www cganet com Code for Safety in Welding and Cutting norme CSA W117 2 de la Ca nadian Standards Association Standards Sales 178 boulevard Rexdale Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou a Toronto 416 747 4044 site Web www csa interna tional org Practice For Occupational And Educational Eye And Face Protection norme ANSI 287 1 de l American National Standards Institute 11 West 42nd Street New York NY 10036 8002 t l phone 212 642 4900 site Web www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work norme NFPA 51B de la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Web www nfpa org et www sparky 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 de l U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bu
35. lames 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 FIRE EXPLOSION hazard 4 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 FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories
36. le les grouper et les poser aussi bas que possible par ex terre e Veiller souder une distance de 100 m tres de tout quipement lectronique sensible e Veiller ce que le poste de soudage soit pos et mis la terre confor m ment au pr sent manuel e En cas d interf rences apr s ex cution des directives pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez dis tance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 303 Page 7 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping norme American Welding Society AWS F4 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 t l phone 305 443 9353 site Web www aws org National Electrical Code norme NFPA 70 de
37. nneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE F risque de causer des interf rences e Le rayonnement haute fr quence peut causer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs e Ne demander qu des personnes qualifi es familiaris es avec les quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences caus es par l installation e Sila Federal Communications Commission signale des interf ren ces arr ter imm diatement l appareil e Faire r guli rement contr ler et entretenir l installation e Maintenir soigneusement ferm s les panneaux et les portes des sour ces de haute fr quence maintenir le jeu d clatement au r glage ad quat et utiliser une terre et un blindage pour r duire les interf ren ces ventuelles LE SOUDAGE L ARC peut causer des interf rences e L nergie lectromagn tique peut causer des interf rences avec 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 compati ble au point de vue lectromagn tique e Pour r duire la possibilit d interf rence maintenir les c bles de sou dage aussi courts que possib
38. nsportation 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 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
39. onnexions e V rifier fr quemment le cordon d alimentation et s assurer qu il n est ni endommag ni d nud le remplacer imm diatement s il est en dommag tout c ble d nud peut causer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser de c bles us s endommag s de calibre insuffisant ou mal piss s e Ne pas s enrouler les cables autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode d une autre machine som fre 8 03 AEN Ce groupe de symboles signifie Mise en garde Faire preuve de vigi lance a des dangers li s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Se reporter aux symboles et aux directives ci dessous afin de conna tre les me sures prendre pour viter tout danger e N utiliser que du mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment au pr sent manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de fa on obtenir un bon contact m tal sur m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e pas connecter plus
40. ons ere a e RR Ye ERREUR Va PR ERR A IU TCU 12 5 3 Typical TIG Connections ette acids Soha Wad Yu MES Dew ww a AES AER RI NOE RUE Y 13 5 4 Electrical Service Guide 14 5 5 Connecting Input POWE rende rent poer qe RUN X YA UP A 14 SECTION 6 2 RERUMS E Eme E eig Ee 15 6 1 user Ehe E hired pide hostels 15 6 2 Example of Front Panel Amperage Control 2 16 6 3 Example of Remote Amperage Control 16 6 4 Process and Material Thickness Guide Label 17 SECTION 7 MAINTENANCE AND TROUBLESHOOTING 18 751 Routine Maintenance nos iced ce este ER ERE EE EE RE ER Re Roe 18 7 2 Troubleshooting m dpa ee pb a PER a BAWUESi EE 18 SECTION 8 ELECTRICAL DIAGRAMS 19 SECTION 9 HIGH FREQUENCY dE AER De T Os d 20 9 1 Welding Processes Requiring High 20 9 2 Incottect Installatior o wives de rebond DUE re a eR esas 20 9 3 Gorrect Installation nis a cer petere
41. ore 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 not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged par
42. ossible de la zone de soudage Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur m decin Si ce dernier les d clare aptes il leur est recom mand de respecter les consignes ci dessus SECTION 3 DEFINITIONS General Precautionary Label 3 1 ARC WELDING can be hazardous e Read and follow all labels and the Owner s Manual carefully e Only qualified persons are to install operate or service this unit according to all applicable codes and safety practices e Keep children away e Pacemaker wearers keep away e Welding wire and drive parts may be at welding voltage Do Not Remove Destroy Or Cover This Label ELECTRIC SHOCK can kill e Always wear dry insulating gloves e Insulate yourself from work and ground e Do not touch live electrical parts e Disconnect input power before servicing e Keep all panels and covers securely in place FUMES AND GASES can be hazardous e Keep your head out of the fumes Ventilate area or use breathing device Read Material Safety Data Sheets MSDSs manufacturer s instructions for materials used UN CHOC ELECTRIQUE peut etre mortel e Insallation et raccordement de cette machine doivent etre conformes a tous les pertinents Read American National Standard Z49 1 Safety In Welding Cutting and Allied Processes From American Welding Society 550 N W LeJeune
43. r agr LES PIECES CHAUDES peuvent cau ser des br lures graves e Ne pas toucher les pi ces chaudes main nue e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent perturber le fonctionnement des stimu lateurs cardiaques e Les personnes qui portent un stimulateur cardiaque doivent se tenir distance e 15 doivent consulter leur m decin avant de s appro cher d un lieu o on ex cute des op rations de sou dage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit de certains processus et quipements peut affecter l ouie e Porter des protecteurs d oreille agr s si le niveau Sonore est trop lev Les BOUTEILLES endommag es peuvent exploser Les bouteilles de gaz protecteur contiennent du gaz sous haute pression Toute bouteille endommag e peut exploser Comme 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 de la chaleur excessive des chocs m caniques du laitier des flammes nues des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire 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 cir cuits lectriques Ne jamais poser une torche de
44. r 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 303 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 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 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 eq
45. r 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 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 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire
46. reaux r gionaux T l phone pour la R gion 5 Chicago 312 353 2220 site Web www osha gov 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et les effets des champs magn ti ques basse fr quence sur l organisme En parcourant les c bles de soudage le courant cr e des champs lec tromagn tiques Les effets potentiels de tels champs restent pr occupants Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit de sp cialistes du National Research Council a conclu L accumula tion de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectriques haute fr quence constitue un risque pour la sant humaine Toutefois les tudes et l examen des preuves se poursuivent En attendant les conclusions finales de la re cherche il serait souhaitable de r duire l exposition aux champs lectromagn tiques pendant le soudage ou le coupage OM 303 Page 8 Afin de r duire les champs lectromagn tiques en milieu de travail res pecter les consignes suivantes 1 Garder les c bles ensemble en les torsadant ou en les fixant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos l op rateur 3 Ne pas s enrouler les c bles autour du corps 4 Garder le poste de soudage et les c bles le plus loin possible de soi 5 Placer la pince de masse le plus pr s p
47. rference keep weld cables as short as possible close together and down low such as on the floor 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 Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive 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 OM 303 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 7491 from Global Engineering Documents phone 1 877 413 5184 website www global ins 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 Box 9101 1 Battery March Park Quincy 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of Compressed Gases in Cylinders CGA
48. t sieur ere rena Bus aa abe Ge al ele he ERR E Re RR E 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de s curit 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS aea E TERRE redire ames EEN 9 3 1 General Precautionary 1 9 SECTION 4 INTRODUCTION 4 i veiw een dire MN EEN dla 10 4 1 Included with Your Unit 4 reo eamm eem e img ds Ux RR XAR RS URN Eed E 10 4 2 Specifications a oorr e e ERROR sin coo aw aan dake 11 4 3 Duty Cycle Chart ea eee a eR EMG QUERN QNUM ates Cep Am PATER 11 4 4 Volt Ampere GUrVves sre e DR EYE V ee aed EISE GUN RUP Y 11 SECTION 5 INSTALLATION eeschte EE dE eet EU 12 5 1 Selecting A Eecation ru ru eG HIE SP 12 5 2 Typical Stick Connecti
49. toucher aux pi ces lectriques sous tension Porter des gants et des v tements de protection secs et exempts de trous e S isoler de la pi ce et de la terre au moyen de tapis ou autres disposi tifs isolants suffisamment grands pour emp cher tout contact physique avec la pi ce ou la terre Ne pas se servir d une source de courant alternatif dans les zones humi des les endroits confin s ou l o on risque de tomber e Ne se servir d une source de courant alternatif QUE si le proc d de souda ge l exige e GSil tilisation d une source de courant alternatif s av re n cessaire se ser vir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil Couper tiqueter l alimentation selon la norme OSHA 29 CFR 1910 147 voir les nor mes de s curit e Installer et mettre la terre correctement l appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours v rifier la terre du cordon d alimentation V rifier et sassu rer 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 Pour ex cuter les branchements d entr e fixer d abord le conducteur de mise la terre ad quat et contre v rifier les c
50. ts at once Maintain unit according to manual 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 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 o
51. ts in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby EIC 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 303 Page 2 a BUILDUP OF GAS can injure or kill 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 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 f
52. uipment 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 Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Follow requiremen
53. uits 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 volt 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 bef
54. ut of unit as limited by Amperage control Built in arc starter comes on when needed to start or stabi lize welding arc No adjustments needed for arc starter 2 Pilot Light 3 Power Switch Use switch to turn unit fan and pilot light On and Off 4 Amperage Control For Stick SMAW use control to adjust amper age within range selected by the Range Polar ity Switch 5 Stick SMAW Table Use table to find approximate Stick amperage output at Amperage control setting See Section 6 2 for example of front panel am perage control For remote amperage control used when TIG GTAW welding front panel Amperage control setting is the maximum amperage percentage available at the remote control device See Section 6 3 for example of remote amper age control 6 Range Polarity Switch Use switch to select range and polarity of weld output Ref ST 155 790 F For Direct Current Electrode Negative DCEN use Electrode Negative position For Direct Current Electrode Positive DCEP use Electrode Positive position For alternating current AC use range needed for welding application AC Low or AC High position see Warning See Section 6 4 to find suggested type of weld output for application 7 High Temperature Shutdown Light Lights when unit overheats and shuts down see Section 7 2 8 Output On Contactor Light Lights when output contactor and unit power are on OM 303 Page 15 6 2
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