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Miller Electric 852 Welder User Manual

1. Copper Bar OM 222 Page 18 7 A complete Parts List is available at www MillerWelds com 4 10 Remote 14 Receptacle Information Socket Information OUTPUT A 24 volts ac Protected by supplementary protector CB2 CONTACTOR B Contact closure to A completes 24 volts ac contactor control circuit C Command reference O to 10 volts dc REMOTE OUTPUT CONTROL D Remote control circuit common E O to 10 volts dc input command signal from remote control F Current feedback 1 volt per 100 amperes A N AMPERAGE VOLTAGE H Voltage feedback 1 volt per 10 arc volts OUTPUT 115 volts 15 amperes 60 Hz ac Protected by supplementary protector CB1 115 VOLTS AC CONTACTOR J Contact closure to completes 115 volts ac contactor control circuit GND K Chassis common G Circuit common for 24 and 115 volts ac circuits REMOTE POWER ON OFF To remote On Off switch REMOTE VOLTAGE SENSING Voltage sensing signal from Negative weld output terminal Voltage sensing signal from Positive weld output terminal Not Used 4 11 Connecting Remote Control 1 Remote 14 Receptacle RC8 Connect remote control to RC8 EA E Ref ST 800 101 D ST 141 127 D OM 222 Page 19 E A complete Parts List is available at www MillerWelds com 4 12 Electrical Service Guide 60 Hertz Models 300 Amp Model 450 Amp Model 650 Amp Model In
2. Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e 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 lf interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause A Engine exhaust contains chemicals known to the State of birth defects and in some cases cancer California Health amp California to cause cancer birth defects or other reproductive Safety Code Section 25249 5 et seq harm For Gasoline Engines For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer
3. quipements peut affecter l ouie e Porter des protecteurs d oreille agr s si le niveau sonore est trop lev Les BOUTEILLES peuvent exploser Les bouteilles de gaz protecteur contiennent du gaz sous haute pression Toute bouteille endommag e peut exploser Comme les bouteiles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution endommag es 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 e Ne jamais poser une torche de soudage sur une bouteille de gaz e Ne 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 tiliser 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 D tourner la t te lorsqu on ouvre la soupape d une bouteille 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
4. Close and secure access door or go on to Section 4 14 200 VOLTS 230 VOLTS 460 VOLTS A o AA AAAA A o AR RAR GIR ARARO ooo ocofffoo coffoo o ofi ARARO ooo o Ref S 174 976 B 230 VOLTS 460 VOLTS 575 VOLTS ARA AAAA RAROS coco ooo ffhccc cccfff ccccffh ocoooff RAR o o offic o o o oo ofi Ref S 174 973 B 220 VOLTS 380 VOLTS 400 VOLTS 440 VOLTS I ooo of ooo o fidooollooofdo ooofff jo oooffolloofiloo oo ldoo oofffico ofp oo o o0 oo o o Ao o FACTORY OPTION Ref S 174 975 B A AN E So Tools Needed J 3 8 in Do not overtighten jumper link nuts C H0 3 8 in Ref ST 800 103 A OM 222 Page 21 E A complete Parts List is available at www MillerWelds com 4 14 Connecting Input Power Installation must meet all National and Local Codes have only quali fied persons make this installation Disconnect and lockout tagout in put power before connecting input conductors from unit GND PE Earth Ground Make input power connections to the welding power source first Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal See rating label on unit and check input voltage available at site 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 4 12 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage
5. ELECTRIC SHOCK HAZARD SECTION 7 ELECTRICAL DIAGRAM Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit OPTIONAL PRIMARIES GROUND CURRENT SENSE OPTION 380 400 440 200 230 460 PRIMARY PRIMARY r O REED 2 5 i TURNS 2 FACTORY OPTION Cnil L OND i 4 d TO FAN O CIRCUIT ae AB TO FAN 5 10 iR CIRCUIT W CH e B m z 7 Q E W 392 3 t t gt 1 O O W 21 B e mm E rh mo FROM CONTACTOR D DR SWITCH G S 4 FROM CONTACTOR Q 18 KC8 YEL IOR SWITCH ei 27 La CFV gt a gt BR GR SIL E 77 AU 6 H6 AWYA T2 B Z4V FROM INPUT FROM INPUT POWER STA POWER 43 A A A A A E 1 RC amp K G A OM 222 Page 26 Figure 7 1 Circuit Diagram PA ie 3 ELECTRODE 4 21 SMAW A y nn ZE a O 7 A SESS 78 ES gt y B lt MODEL 302 AND 452 ljo C4 gt PA TEN Pe USES SINGLE COIL Z1 TTAN A PLE Wi Vz s Y USES DUAL OIL lod PEE a x se scr DIT gt 1 2 E NE 5l p b NI co I o E m SR1 E I S 271 jl s sefa i l
6. ELM E RC7 e 5 9 04 13 1551211 FOZ np 610 ci CZ WORK SER SER SER SMAW zs 4 5 6 gt 551 9 e O amp N N t S EX SX UMEN DUE y TS A NN N STAW ER x 5454 O e 8 ange aO mcis RO8 Sou SHER al EE a i rea EL retos aM RC4 85 5 77 RCI 1 7 TER reas lt lt Rcii g HARD Pal gt lt CONTROL BOARD ques is RETE RC1 PLG1 ROS PLGS NTC NE TUE RC10 3 AS aps RCe PLGO gt 43 lt RC10 2 RCS 14 gt hi TA E E V V ia 4 OPTIONAL K E A A CE CEN C d 7 x perc 25 i5 SHOWN M REAR h SMTCH FOR CC ATAW POSITION CONTACTS ARE ROTATED ONE POSTON CLOCKWISE GS 302 USES 55A ONLY WARK STUB ELECTRODE STUD STABILIZER RECTIFIER NEGATIVE CONTROL PLG7 VAN RC7 Ory PL 2 qu 2 DE __ERS al ll a D a CRS O w Bl 4 45 3 pu O e J Premote E tra is USED Wim POWER 1 GROUND CURRENT ON OFF L_SENSOR OPTION _ 4 ROB J B C F H 218 518 A OM 222 Page 27 SECTION 8 PARTS LIST NOTE A complete Parts List is available on line at www MillerWelds com FSELECT Parts 2 Consumables T RAS VA eL R Finding the right parts and Download Owner s consumables has never Manuals for complete been easier parts listing Notes OM 222 Page 28 http www millerwelds com service replacementparts html Choose Genuine Select to review spare parts requirements such as filters spark plugs and fuses C
7. diatement s il est en dommag tout c ble d nud peut causer une lectrocution respirateur a 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 e Ne pas souder proximit d op rations de 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 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 tante mal piss s e Ne pas souder de m taux munis d un rev tement tels que la t le e Ne pas s enrouler les c bles autour du corps d acier galvanis e plomb e ou cadmi e moins que le rev tement e Sila pi ce soud e doit tre mise a la terre le faire directement avec un n ait t enlev dans la zone de soudage que l endroit soit bien venti c ble distinct l et si n cessaire porter un respirateur a adduction d air Les e Ne pas toucher l lectrode quand on est en contact avec la pi ce la rev tements et tous les m taux renfermant ces l ments peuvent d terre ou une lectrode d une autre machine gager des fum es toxiques lorsqu on les soude OM 222 Page 5 LES RAYONS DE L ARC peu
8. AAA E AA ATA SU AA ar 15 4 5 Dimensions And WeIGMS i oe d AR dre ER AR REX See Lee REPE xA SE ga 16 2 25 2 9 LE cas o ertet d fere onu n RR NT c gita 17 4 7 115 VAC Receptacle And Supplementary Protectors 17 4 8 Weld Output Terminals And Selecting Cable Sizes 18 4 9 Connecting Weld Output Cables 0 0 ccc eee nnn 18 4 10 Remote 14 Receptacle Information l l 19 4 11 Connecting Remote Control i sou sre ce Re Gg eR DC RO awe a ace SC oi ate Red 19 4 12 Electrical Service Guide iua uc m t Ra oon ewe nee C e en e OE ac b ae V at 20 2 13 Placing Jumper LINKS aos abs Pc oe eed hae ain Sg Op tre Scipio S bo dace cebra 21 4 14 Connecting Input POWER wees eae Rob ACER e e c n oi c e odes 22 SECTION 5 OPERATION eves zc A AAA 23 5 Gontrels Non GE Models sau an Miss MEE AGES AAA en Suec PAN d 23 9 2 Gontrols CE MOd IS s uid qos ove eus eee Se grado AAA d tc i Are 24 SECTION 6 MAINTENANCE AND TROUBLESHOOTING eee nnns 24 6 1 Routine Maintenance sis o REDE Ec CHE Dre x ome em bees esa 24 0 2 FUSE gq EROR EET A tert edunt ie eMe tiw ei ded dte imo a ake LIE 25 6 9 TMOUDICSHOOUNG 2 c0 a2 ERE ESPERA RIS REM RE Eae n En ao INN dA US 25 SECTION 7 ELECTRICAL DIAGRAM x 33x x Wai d A A c ee ee mode n cl E 26 SECTION 8 PAHTS EIST i ura caer oe xD e Un n OE A AA ro ous EE RUE E Pus eer
9. Arc Force Dig Control Control increases SMAW short circuit amper age which allows the operator to use a very SECTION 6 MAINTENANCE AND TROUBLESHOOTING 6 1 Routine Maintenance A Disconnect power before maintaining Replace Repair or Clean and unreadable replace tighten weld labels cracked terminals a weld cable 6 Months Blow out or vacuum inside During heavy service clean monthly OM 222 Page 24 6 2 Fuse F1 Tools Needed C ZH 3 8 in E A complete Parts List is available at www MillerWelds com Turn Off power before open ing rear access door Fuse F1 See Parts List For Rating Fuse F1 protects control transform er from overload If F1 opens weld output and fan motor stops Re place F1 Close and secure access door Ref ST 800 101 C Trouble Remedy No weld output unit completely inop erative Place line disconnect switch in On position see Section 4 14 Check fuse F1 and replace if necessary See Section 6 2 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 14 Check for proper input power connections see Section 4 14 Check for proper jumper link position see Section 4 13 No weld output Power switch pilot light on fan on If using remote control place Output Contactor switch in Remote 14 position and
10. Ios and easy With Miller you can count on years Ni 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 SU oA ba cad exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web ur Miller Mil_Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 ad OY MPSS AO O ae ae Rae ae ee hae tad li db sd een ade eae 1 152 Are Welding Hazard 2 o oe e kaa Ae de a aa alee Dio aie do qua 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 1 3 555 P ncipal Satety Standards es curn die Peer Dept das Vere gi ri
11. OM 222 Page 11 7 A complete Parts List is available at www MillerWelds com 3 6 Symbols And Definitions Note E Some symbols are found only on CE products Amperes Gas Tungsten Arc j Welding GTAW Do Not Switch LL Shielded Metal Arc o Welding SMAW O e O Percent Output O O Circuit Breaker Remote V Volts Protective Earth o gt H Rated No Load U Primarna Conventional Load Voltage Average 1 Lt D Voltage Rated Welding 2 Current T Primary Current Duty Cycle Degree Of Protection 3 AL hree Phase Electrode Wire Feeder Connection OM 222 Page 12 Three Phase Transformer Rectifier Work Connection Do not discard product where ap plicable with general waste Reuse or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information E A complete Parts List is available at www MillerWelds com SECTION 4 INSTALLATION 4 1 Specifications Rated Maximum Amperes Input at Rated Load Output 50 or 60 Hz Model Welding Amp Open IP Three Phase Range DC Circuit Rating Sarpur Voltage DC 200V 230V 380V 400V 440V 460V 575V KVA KW 300 A 300 32 Volts 15 395 68 21M 70 61 35 33 31 31 25 24 5 13 8 Amp DC 6096 70 4 0 3 6 vas 1 1 1 0 C d 15 1 3 0 67 Duty Cycle 450A 450 38 Volt
12. Rating In Amperes 1 Time Delay 2 40 40 35 60 60 50 90 80 80 Normal Operating 3 60 50 50 80 80 70 125 110 100 Min Input Conductor Size In AWG 4 10 10 10 8 8 8 6 6 6 Max Recommended Input Conductor Length 243 269 326 218 241 292 219 242 293 In Feet Meters 74 82 99 66 73 89 67 74 89 Min Grounding Conductor Size In AWG 4 10 10 10 8 8 8 6 6 8 Reference 2005 National Electrical Code NEC 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 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 OM 222 Page 20 E A complete Parts List is available at www MillerWelds com 4 13 Placing Jumper Links A Disconnectand lockout tag out input power before installing or moving jumper links Check input voltage available at site 1 Jumper Link Label Check label only one is on unit 2 Jumper Links Move jumper links to match input voltage
13. birth defects and other reproductive harm 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 OM 222 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 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 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 b
14. de mani puler des cartes ou des pi ces e Utiliser des pochettes et des boites antistatiques pour stocker d placer ou exp dier des cartes de circuits imprim s LES PIECES 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 LES ORGANES MOBILES peuvent causer des blessures e Setenir l cart des organes mobiles comme les ventilateurs e Maintenir ferm s et bien fix s les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H 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 Ne demander qu des personnes qualifi es familiaris es avec les quipements lectroniques de faire fonctionner l installation L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences caus es par l installation Si la Federal Communications Commission signale des interf ren ces arr ter imm diateme
15. eee c 28 OPTIONS AND ACCESSORIES WARRANTY Declaration of Conformity for European Community CE Products Manufacturer European Contact Miller Electric Mg Co Mr Danilo Fedolfi 1635 W Spencer St Managing Director Appleton WI 54914 USA ITW Welding Products Italy S r l Phone 920 734 9821 Via Privata Iseo 6 E 20098 San Giuliano Milanese Italy Phone 39 02 98290 1 Fax 39 02 98290203 dose Declares that the product G O d sta r R 402 3 602 3 An d 352 conforms to the following Directives and Standards European Contact Signature Directives Electromagnetic compatibility Directives 89 336 EEC 92 31 EEC Low Voltage Directive 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Safety Requirements for Arc Welding Equipment part 1 EN 60974 1 1990 Arc Welding Equipment Part 1 Welding Power Sources IEC 974 1 April 1995 Draft revision Degrees of Protection provided by Enclosures IP code IEC 529 1989 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC 664 1 1992 Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 August 1995 dec stat 6 05 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 Symbol Usage i Marks a special safety
16. 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 e Ne pas placer l appareil sur une surface inflam mable ni au dessus ou proximit d elle e Ne pasinstaller l appareil proximit de produits inflammables e 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 Nutiliser que l anneau de levage pour lever lap pareil NE PAS utiliser le chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin de capacit ad quate pour lever l appareil e Si on 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 L EMPLOI EXCESSIF peut FAIRE SURCHAUFFER L EQUIPEMENT 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 e Ne pas obstruer les orifices ou filtrer l alimentation en air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s E lt lt i e Mettre un bracelet antistatique AVANT
17. prot ger et prot ger les tiers de la projection d tincelles et de m tal chaud e Ne pas souder un endroit ou 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 e 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 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 Encas 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 rev
18. sont utilis s tout au long du pr sent e 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 apres ne font que r sumer le o contenu des normes de s curit mentionn es la section 2 4 Lire et respecter toutes ces normes 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 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 facon 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 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 e Ps LES D CHARGES LECTRIQUES e 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
19. soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact Ne pas connecter plus d une lectrode ou plus d un c ble de masse un m me terminal de sortie Il 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 avec le fil de soudage sont sous tension Tout mat riel mal install ou mal mis la terre pr sente un danger Ne jamais toucher aux pi ces lectriques sous tension Porter des gants et des v tements de protection secs et exempts de trous 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 Ne se servir d une source de courant alternatif QUE si le proc d de souda ge l exige Si l utilisation 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 charger les condensateurs d alimentation selon les instructions nonc es la section 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 de
20. static proof bags and boxes to store move or ship PC boards 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 STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans 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 f notified by the FCC about interference stop using the equipmentat once
21. 85 mm 38 in 966 mm including strain relief 27 1 2 in 699 mm 35 in 889 mm 35 in 889 mm 3 4 in 19 mm 1 1 4 in 32 mm 1 1 4 in 32 mm 21 1 8 in 537 mm 21 1 8 in 537 mm 21 1 8 in 537 mm 1 1 8 in 29 mm 1 1 8 in 29 mm 1 1 8 in 29 mm IIO nn m oc ou gt 7 16 in 11 mm Dia 7 16 in 11 mm Dia 7 16 in 11 mm Dia Weight 352 Ib 160 kg OM 222 Page 16 404 Ib 183 kg 505 Ib 229 kg 4 Holes 800 453 A 801 530 7 A complete Parts List is available at www MillerWelds com 4 6 Tipping A Be careful when placing or moving unit over uneven surfaces 4 7 115 VAC Receptacle And Supplementary Protectors A Turn Off power before connecting to receptacle 1 115V 15A AC Receptacle RC9 Power is shared between RC9 and Remote 14 receptacle RC8 see Section 4 11 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects the 115 volts ac por tion of RC8 and RC9 from overload CB2 protects the 24 volts ac portion of RC8 Press button to reset protector Ref ST 800 101 D OM 222 Page 17 E A complete Parts List is available at www MillerWelds com 4 8 Weld Output Terminals And Selecting Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding wongomortess eo zr zoe soo
22. APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the
23. Educational Eye And Face Protection norme ANSI Z87 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 bureaux 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 Laccumula tion de preuves n a pas d montr que l exposition aux champs magn tiques et aux champs lectr
24. ICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power e 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 e lfinside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any
25. OM 222 164 850AD 2007 03 EE Miller O TIG GTAW Welding nm Stick SMAW Welding re Flux Cored FCAW Welding A Air Carbon Arc CAC A M Cutting and Gouging Description e a El Arc Welding Power Source c Gold Star Series 302 452 652 60 Hz 402 602 852 50 Hz OWNER S MANUAL File Stick SMAW Pu Visit our website at www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 Ir Y E BL El Her This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They LUE El jue EE You e f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick icai eue uus
26. R 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 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Tech
27. capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief 1 Route conductors cord through strain re lief and tighten screws 3 Machine Grounding Terminal 4 Green Or Green Yellow Grounding Conductor IMPORTANT 5 Reed Switch Ground Current 3 Sensor Optional 6 Input Contactor Connect green or green yellow grounding conductor to welding power source grounding terminal first If unit is equipped with optional ground current sensor route grounding conductor through reed switch two times and connect to grounding termi nal 6 Welding Power Source Line Terminals 7 Input Conductors L1 U L2 V And L3 W Connect input conductors L1 U L2 V and L3 W to welding power source line GND PE Earth Ground terminals Close and secure access door on welding power source Disconnect Device Input Power Con nections 8 Disconnect Device switch shown in OFF position 9 Disconnect Device Supply Grounding Terminal Connect green or green yellow grounding conductor to disconnect device grounding terminal first Tools Needed 10 Disconnect Device Line Terminals 0 j SB Connect input conductors L1 U L2 V CO 3 8 in And L3 W to disconnect device line terminals E 11 Over Current Protection Select type and size of over current protection using Section 4 12 fused dis connect switch shown Close and secure door on line disco
28. connect remote control see Section 4 11 If remote is not being used place switch in On position Check repair or replace remote control Unit overheated Allow unit to cool with fan On see Section 4 2 Have Factory Authorized Service Agent check control board PC1 No weld output Power switch pilot light on fan off Check for proper input power connections see Section 4 14 Check and replace line fuse s if necessary or reset circuit breaker see Section 4 14 Have Factory Authorized Service Agent check SCR s Unit provides only maximum or mini mum weld output Have Factory Authorized Service Agent check control board PC1 and hall device HD1 Erratic or improper weld output Use proper size and type of weld cable see Section 4 8 Clean and tighten all weld connections Check position of Polarity selector switch see Section 5 1 Have Factory Authorized Service Agent check control board PC1 and hall device HD1 No 115 volts ac output at duplex recep tacle Remote 14 receptacle Reset supplementary protector CB1 see Section 4 7 No 24 volts ac output at Remote 14 re ceptacle Reset supplementary protector CB2 see Section 4 7 Fan not operating NOTE fan only runs when cooling is necessary Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor OM 222 Page 25 WARNING
29. d 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 oylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit HE 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 f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit e Puton grounded wrist strap BEFORE handling boards or parts e Use proper
30. dad noz a 4 156 EME TORAH OM asser d oes abled td b oe aa Dea Ee V d a ir 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles us pac ira bcd rd e oodd dd os ee dete pelos doses recon Quat ae NC pU e 5 2 2 Dangers relatifs au soudage l arc 2 5 2 3 Autres symboles relatifs l installation au fonctionnement et l entretien de l appareil 7 2 4 Principales normes de SecUrite us tie Raus ele dat s OS ahs il Gt AAA NO De 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS 1 252 xat RS RR a a ARA 9 3 1 General Precautionary Label enna hh hh tre 9 2 APUL CONNECCION Label orar t aset ON es atta re Baba Da dette dE eee we 10 9 9 Electric shock And Airlow Label du da ped RR d ee tedio dara eats ee eae Era 10 3 4 Nameplate Salely Symbols Ses d unc aue d eq heh Utd AR db que Oe ae am 10 3 7 WEEE Label For Products Sold Within The EU 0 cc eens 12 SECTION 4 INSTALLATION 5 aia ac a eR ao AI t E I RE diamond 13 AT SPCCIICAUOMS 103 d xt E eae em AR DE eo 3d E EE RU i C cR ob darn 13 4 2 Duty Cycle And Overheatlhg erresires v ERR X ed ee eh AGREE A A a ee eek ek 13 4 3 Volt Ampere QUIVOS a cca rendra UR ARRA Edd REEF EP PLN TEES E ARA aa 14 4 4 Selecting A Location 22 RE A
31. een 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 222 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 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 Governm
32. ent 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 Keepcables 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 B m 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 SECURITE A LIRE AVANT UTILISATION som_fre 8 03 2 1 i A identifie un message de s curit particulier 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 directives Ce groupe de symboles signifie Mise en garde Faire preuve de vigi lance Il y 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 connaitre les me Signifie NOTA n est pas relatif la s curit sures prendre pour viter tout danger 2 2 Dangers relatifs au soudage a l arc A Les symboles ci apr s
33. 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 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 O
34. ers 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 gt gt vent blesser les yeux e Le soudage le burinage le passage de la pi ce a 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 e Porter des lunettes de s curit crans lat raux agr s m me sous le masque de soudage OM 222 Page 6 LES ACCUMULATIONS DE GAZ peu vent causer des blessures ou m me la mort e Couper l alimentation en gaz protecteur en cas de E non utilisation e Veiller toujours bien ventiler les espaces confin s ou porter un respira teur adduction d air 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 lls 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
35. f output place switch in Panel position For remote control of output place switch in Remote position and connect remote device see Section 4 11 A Turn Off power before connecting re mote device OM 222 Page 23 E A complete Parts List is available at www MillerWelds com 5 2 Controls p Models 1 Polarity Selector Switch Optional On 50 Hz Models To change polarity on models not equipped with a Polarity Selector switch reverse work and electrode cables at the weld output termi nals see Section 4 8 A Turn Off Power before reversing 300 Amp Model Shown short arc length without sticking the electrode Set control at O for normal welding amperage Turn clockwise to increase short circuit amperage 3 HotStart Switch Turn switch On for SMAW and Off for GTAW welding Ref ST 173 450 B 8 Remote Amperage Control Switch For front panel control place switch in Panel position For remote control place switch in Remote position and connect remote device see Section 4 11 9 Output Switch Contactor For front panel control of output place switch in Panel position For remote control of output place switch in Remote position and connect remote device see Section 4 11 A Turn Off power before connecting re mote device 4 Amperage Adjustment Control 5 Digital Meters Optional 6 Power Switch With Indicator Light 7 High Temperature Shutdown Light cables 2
36. hoose Service Parts to download complete parts listing 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 GQ Miller Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time M
37. iller 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 delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated ntellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls nduction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except
38. iques 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 tiquespendant le soudage ou le coupage OM 222 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 possible 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 E A complete Parts List is available at www MillerWelds com 3 1 General Precautionary Label Warning Watch Out There are possible hazards as shown by the symbols 1 Electric shock from welding electrode or wiring can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from electric shock by insulating you
39. message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols 7 Means Note not safety related 1 2 Arc Welding Hazards A 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 A During operation keep everybody especially children away m ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical c
40. 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 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 requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby ou E 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 222 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas s
41. metals containing these elements can give off toxic fumes if welded OM 222 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 749 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 T WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot
42. n ason soon eno pcia fo weld output Prat Duty bur edd 10 100 Duty Cycle terminals Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 9 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 300 1 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 350 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 3 0 2 4 0 400 1 0 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 2 4 0 Electrode Work 500 2 0 3 0 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 3 0 IN 9 600 3 0 4 0 2 2 10 2 30 2 40 3 30 3 40 3 4 0 700 4 0 2 2 0 2 3 0 2 4 0 3 3 0 3 4 0 3 4 0 4 4 0 800 4 0 2 2 0 2 3 0 2 4 0 3 4 0 3 4 0 4 4 0 4 4 0 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 S 0007 D 4 9 Connecting Weld Output Cables Do not place anything between weld cable terminal and copper bar Tools Needed Y2 TT 3 4 in 19 mm 803 778 B Correct Installation Incorrect Installation A Turn off power before connecting to Weld Output Terminal minal Slide weld cable terminal onto weld weld output terminals output terminal and secure with nut so that pe UP nad weld cable terminal is tight against copper A Failure to properly connect weld Weld Cable Terminal bar Do not place anything between weld cables may cause excessive heat 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
43. nical 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 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com GQ Miller
44. nnect device Remove lockout tagout device and place switch in the On position 800 103 C Ref 801 116 A OM 222 Page 22 5 1 DO NOT SWITCH UNDER LOAD OR WITH OUTPUT ON Q T OUTPU short arc length without sticking the electrode 1 Polarity Selector Switch Optional On 50 Hz Models To change polarity on models not equipped with a Polarity Selector switch reverse work and electrode cables at the weld output termi nals see Section 4 8 A Turn Off Power before reversing cables 2 Arc Force Dig Control Control increases SMAW short circuit amper age which allows the operator to use a very ARC FORCE HOT CONTRO E A complete Parts List is available at www MillerWelds com SECTION 5 OPERATION Controls NOR CE models 300 Amp Model Shown ded ADJUST ME un Set control at O for normal welding amperage Turn clockwise to increase short circuit amperage 3 Hot Start Switch Turn switch On for SMAW and Off for GTAW welding 4 Amperage Adjustment Control 5 Digital Meters Optional 6 Power Switch With Indicator Light 7 High Temperature Shutdown Light High Temp Shutdown Q on Ref ST 165 596 D 8 Remote Amperage Control Switch For front panel control place switch in Panel position For remote control place switch in Remote position and connect remote device see Section 4 11 9 Output Switch Contactor For front panel control o
45. nt l appareil Faire r guli rement contr ler et entretenir l installation 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 Veiller ce que tout l quipement de la zone de soudage soit compati ble au point de vue lectromagn tique Pour r duire la possibilit d interf rence maintenir les c bles de sou dage aussi courts que possible les grouper et les poser aussi bas que possible par ex terre Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que le poste de soudage soit pos et mis la terre confor m ment au pr sent manuel 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 e Porteurs de stimulateur cardiaque reste
46. ontact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling e Use AC output ONLY if required for the welding process e f AC output is required use remote output control if present on unit e Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground 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 e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owners Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle
47. outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill 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 e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in place e Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIF
48. put Voltage 200 230 460 575 200 230 460 575 230 460 575 Input Amperes At Rated Output 70 61 31 25 102 89 45 36 124 62 50 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 80 70 35 30 125 110 50 45 150 70 60 Normal Operating 3 110 90 45 35 150 125 70 50 175 90 70 Min Input Conductor Size In AWG 4 6 8 10 12 4 4 8 10 3 8 8 Max Recommended Input Conductor 149 131 356 342 136 180 319 335 144 210 328 Length In Feet Meters 45 40 108 104 41 55 97 102 44 64 100 P NL Conductor Size In 6 8 10 10 6 6 8 10 6 8 8 Reference 2005 National Electrical Code NEC 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 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 50 Hertz Models 300 Amp Model 450 Amp Model 650 Amp Model Input Voltage 380 400 440 380 400 440 380 400 440 Input Amperes At Rated Output 35 33 31 54 51 47 75 71 65 Max Recommended Standard Fuse
49. r settings fall be tween curves shown va_curvel 4 95 SA 171 221 SA 171 222 SA 171 223 E A complete Parts List is available at www MillerWelds com 4 4 Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit LED If using lifting forks extend forks Movement EE m beyond opposite side of unit 3 Rating Label Non CE Models Only Use rating label to determine input power needs Label located under front access door 4 Plate Label CE Models Only Label located under front access door 5 Rating Label CE Models Only Use rating label to determine input power needs Label located on rear access door see Section 3 5 Location And Airflow 6 Line Disconnect Device Locate unit near correct input pow INPUT SERIAL NO er su STOCKNO PPIY VOLTS A Special installation may be AMPERES required where gasoline or i volatile liquids are present PHASE see NEC Article 511 or CEC Section 20 STOCK NO SERIAL NO OM 222 Page 15 E A complete Parts List is available at www MillerWelds com 4 5 Dimensions And Weights Dimensions 300 Amp Models 450 Amp Models 650 Amp Models 30 in 762 mm including lift eye 30 in 762 mm including lift eye 30 in 762 mm including lift eye 23 in 585 mm 30 1 2 in 775 mm including strain relief 23 in 585 mm 38 in 966 mm including strain relief 23 in 5
50. rself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 5 Become trained and read the instructions before working on the machine or welding 6 Do not remove or paint over cover the label OM 222 Page 9 7 A complete Parts List is available at www MillerWelds com 3 2 Input Connection Label Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring can kill Disconnect input plug or power before working on machine Read the Owner s Manual before working on this machine Consult rating label for input power requirements and check power available at the job site they must match Read Owner s Manual and inside labels for connection point
51. s 20 590 71 21M 102 89 54 51 47 45 36 35 5 23 3 Amp DC 6096 70 3 5 3 1 1 5 1 4 1 2 1 5 1 2 1 2 0 51 Duty Cycle 650 A 650 44 Volts 50 850 71 21M o 124 75 71 65 62 50 49 4 36 Amp DC 60 70 5 2 1 7 1 6 1 5 2 6 2 17 2 1 0 58 Duty Cycle While idling Indicates specification differences for CE models 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min RATED OUTPUT utes that unit can weld at rated load a ee AAA without overheating EI TIE If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding A Exceeding duty cycle can damage unit and void warranty 40 50 60 70 80 90 100 DUTY CYCLE Example 60 Duty Cycle 4 Minutes Resting Overheating TA SI i OR Reduce Duty Cycle duty1 4 95 Ref SA 168 919 Minutes OM 222 Page 13 E A complete Parts List is available at www MillerWelds com 4 3 Volt Ampere Curves OM 222 Page 14 DC VOLTS DC VOLTS DC VOLTS A 300 Amp Model EEE O A O A a a LI Wt PN PA AEE Rene rere L sw perone A o SN 100 150 200 250 300 350 400 450 500 DC AMPERES B 450 Amp Model e ees C 650 Amp Model i AC decer LOL 100 200 300 400 500 600 700 800 900 1000 DC AMPERES Volt ampere curves show mini mum and maximum voltage and amperage output capabilities of unit Curves of othe
52. s and procedures Move jumper links as shown on inside label to match voltage at job site Having a loop of extra length connect grounding conductor first S 179 290 Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying ower p 1 96 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from wiring anc exposed weld terminals can kill Close door before turning on unit 1 96 Warning Watch Out There are possible hazards as shown by the symbols Electric shock from welding electrode or wiring can kill Sparks from arcing electrode can cause explosion or fire disconnect cable for process not in use Read Owner s Manual for connection procedures Electric shock from wiring can kill Disconnect input power before working on unit or making terminal strip connections Nameplate D 179 389 OM 222 Page 10 E A complete Parts List is available at www MillerWelds com 3 5 Manufacturer s Rating Labels For CE Products EN 60974 1 EN 60974 1 15A 11V 375A 25V 20A 11V 565A 32 6V A 60 100 Fat 60 100 MEZEN EZEN E EEN CRETE El 3 8A 3A nm 28 5kVA 23 2kVA 17 9kVA S 174 342 S 174 340 j 50A 12V 815A 34V Match label to one on unit See Section 4 4 94A 75A 58A 90A 71A 55A 82A 65A 50A 62kVA 49 4kVA 38 7kVA S 174 341
53. s gaz dont l inhalation peut tre dangereuse pour la sant e Setenir distance des fum es et ne pas les inhaler e 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 Couper l alimentation ou arr ter le moteur avant de proc der l instal m 7 lation la r paration ou l entretien de l appareil Couper tiqueter e Si la ventilation est insuffisante utiliser un respirateur adduction l alimentation selon la norme OSHA 29 CFR 1910 147 voir les nor d air agr mes de s curit m i e SE cest t T i pee Le e Lire les fiches techniques de sant s curit FTSS et les instruc ee aie aaa ESE EE ado tions du fabricant concernant les m taux les consommables les municipaux rev tements les nettoyants et les degraisseurs e Toujours v rifier la terre du cordon d alimentation V rifier et s assu e Netravailler dans un espace clos que s il est bien ventil ou porter un 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 Pour ex cuter les branchements d entr e fixer d abord le conducteur de mise la terre ad quat et contre v rifier les connexions V rifier fr quemment le cordon d alimentation et s assurer qu il n est ni endommag ni d nud le remplacer imm
54. upply 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 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 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 an
55. vent 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 e 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 e Porter des v tements de protection en mati re durable et ignifuge cuir ou laine et des chaussures de s curit A H LE SOUDAGE peut causer un incen 3 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
56. z 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 222 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 la National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 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 67270u a Toronto 416 747 4044 site Web www csa interna tional org Practice For Occupational And

Miller Electric 852 Welder User Manual

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