OM-2226 189783AL 2010−04 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 115/230/400/460 Volt Models W/AutolineR Arc Welding Power Source R Maxstar 200 SD, DX, And LX (Including Optional Cart And Cooler) CE And Non-CE Models Visit our website at www.MillerWelds.
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.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
TABLE OF CONTENTS SECTION 6 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6-1. Accessing Advanced Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6-2. Programmable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6-3. Output Control And Trigger Functions . . .
DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
Notes
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
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 & 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.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com).
OM-2226 Page 10
SECTION 3 − DEFINITIONS (CE Models) 3-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 2 2.1 2.2 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 2.3 3 1.2 Protect yourself from electric shock by insulating yourself from work and ground. 3.1 1.3 Disconnect input plug or power before working on machine. 1 1.1 2 2.1 3 3.1 3.2 1.
Warning! Watch Out! There are possible hazards as shown by the symbols. 1 2 1 2 4 3 5 V V > 60 s V 3 4 5 6 S-185 836 7 6 9 8 7 8 9 1 1 2 3 ∠ = <60 ° ∠ 4 5 S-179 309-A 2 3 4 5 Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors.
3-3.
SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) ! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
4-3.
4-4. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. 1 1 5 V A C In p u t 140 120 Stick Max Vo lts 100 TIG Max 80 60 40 Stick/TIG Min 20 DIG Max 0 0 50 100 150 200 250 200 250 Amp eres O th e r In p u t V o lt a g e s 140 120 Stick Max Volts 100 TIG Max 80 60 40 Stick/TIG Min 20 DIG .
4-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops, a Help message is displayed (see Section 7-3), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. NOTICE − Exceeding duty cycle can damage unit and void warranty.
4-6. Selecting A Location 1 Line Disconnect Device Locate unit near correct input power supply. Dimensions And Weight 34.7 lb (15.7 kg) - without power cord 37.3 lb (16.9 kg) - with power cord ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 17-1/4 in. (438 mm) 13-3/8 in. (333 mm) 7-9/16 in. (192 mm) Location And Airflow 1 18 in. (460 mm) 18 in.
4-7. Weld Output Terminals And Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size. Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding ! Turn off power before connecting to weld output terminals.
4-8. Remote 14 Receptacle Information A B K J Socket* I A Contactor control +15 volts DC. B Contact closure to A completes 15 volts DC contactor control circuit and enables output. C Output to remote control; 0 to +10 volts DC output to remote control. REMOTE OUTPUT CONTROL D Remote control circuit common. E 0 to +10 volts DC input command signal from remote control.
4-9. Automation 10-Pin Connection (LX Models) Socket F E G I A A Start/Stop B Gas C Output enable D Chassis ground E Final slope − collector F Final slope − emitter G Pulse lockout − collector H Pulse lockout − emitter I Valid arc − collector J Valid arc − emitter D J H Socket Information For 10-Pin Receptacle RC2 C B Ref. ST-802 458 Definitions Of Inputs And Outputs Inputs A - Closure to D starts the weld cycle. Opening closure stops weld cycle.
4-11. Gas Connections 1 Gas Fitting Fittings have 5/8-18 right-hand threads (3/8-19 BSPP on CE units). 2 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 3 4 2 3 4 Regulator/Flowmeter Flow Adjust Typical flow rate is 15 cubic feet per hour (7.1 liters per minute). 1 Connect customer supplied gas hose between regulator/flowmeter and gas fitting on rear of unit. Tools Needed: 11/16, 1-1/8 in., (21 mm) ST-802 452 4-12.
4-13. Stick DCEP (Direct Current Electrode Positive) Connections ! Turn off power before making connections. 1 Negative (−) Weld Output Terminal Connect work lead to negative weld output terminal. 2 Positive (+) Weld Output Terminal Connect electrode holder to positive weld output terminal. 3 Remote 14 Receptacle If desired, connect remote control to Remote 14 receptacle (see Section 4-8). 2 3 1 Ref.
4-14. TIGRunner Connections Cart and cooler are optional equipment. 1 2 Gas Cylinder Chains Secure gas cylinder to cart with chains. Connect gas hose to welding power source (see Section 4-11). Connect work lead and torch to welding power source (see Section 4-12). 3 1 Water-Out (To Torch) Connection Connect torch water-in (blue) hose to welding power source water-out connection. 4 5 Water-In (From Torch) Connection Connect torch water-out (red) hose to welding power source water-in connection.
4-15. Electrical Service Guide . Actual input voltage should not fall below 103 volts AC or rise above 506 volts AC. If actual input voltage is outside this range, unit may not operate according to specifications. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
4-16. Connecting Input Power A. Connecting Three-Phase Input Power ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before connecting input conductors from unit. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. 3 = GND/PE Earth Ground 4 .
B. Connecting Single-Phase Input Power 1 8 ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Disconnect and lockout/tagout input power before connecting input conductors from unit. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. . The Auto-Line circuitry in this unit au- =GND/PE Earth Ground tomatically adapts the power source to the primary voltage being applied.
SECTION 5 − OPERATION 5-1. Controls 1 3 2 6 4 5 9 10 7 8 . For all front panel switch pad controls: press switch pad to turn on light and enable function. . Green on nameplate indicates a TIG function, Gray indicates a Stick function. 1 Encoder Control Use encoder control in conjunction with applicable front panel function switch pads to change values for that function. See Section 5-2. 2 Ammeter And Parameter Display See Section 5-4. 3 Voltmeter See Section 5-5.
5-2. Encoder Control 1 Encoder Control Use control in conjunction with applicable front panel function switch pad to set values for that function. 1 5-3. Amperage Control 1 2 3 3 2 A (Amperage Control) Encoder Control Ammeter See Section 5-13 for Amperage control range. Press Amperage switch pad and turn Encoder control to set weld amperage. Weld amperage setting is also peak amperage when Pulser function is active (see Section 5-9). 1 5-4.
5-5. Voltmeter 1 1 Volt Meter Displays output or open circuit voltage. If output is off, the voltmeter will display a series of three dashes (-−−). Open circuit voltage is displayed if power is on and output is available. 5-6. Process Control 1 Process Control Press switch pad until desired process LED is illuminated: TIG HF Impulse - When selected, a pulsed HF (non-contact) (see Section 5-7) arc starting method is activated. This method can be used with either AC or DC TIG welding.
5-7. Lift-Arc™ And HF TIG Start Procedures Lift-Arc Start When Lift-Arct button light is On, start arc as follows: Lift-Arc Start Method 1 “Touch” 1−2 Seconds 2 1 TIG Electrode 2 Workpiece Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control. Hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. Arc is formed when electrode is lifted.
5-8. Output Control 1 1 Output Control Press switch pad until desired parameter LED is illuminated. RMT STD (Remote Standard) Application: Use Remote Trigger (Standard) when the operator desires to use a foot pedal or finger amperage control (see Section 6-3A). . When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope, and final amps are OM-2226 Page 32 controlled at the remote control, not at the welding power source.
5-9. Pulser Control (DX And LX Models) 1 3 2 Pulser Control Pulsing is available only while using the TIG process, it cannot be selected if the Stick process (see Section 5-6) is active. Controls can be adjusted while welding. Press switch pad to enable pulser. ON - When illuminated, this LED indicates the pulser is on. Press switch pad until desired parameter LED is illuminated. To turn Pulser off, press and release switch pad until the On LED turns off.
5-10. Sequencer Controls (DX Models Only) 1 3 2 Sequencer Control Sequencing is available only while using the TIG process, but is disabled if a remote foot or finger current control is connected to the Remote receptacle while in the RMT STD mode. Sequencer parameters cannot be selected if the Stick process (see Section 5-6) is active. Press switch pad until desired parameter LED is illuminated.
5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge) 1 Adjust Press switch pad until desired function LED is illuminated. 3 2 3 2 Encoder Control Ammeter Turn encoder (see Section 5-2) to set appropriate value for active Adjust parameter. Value selected is shown on the ammeter (see Section 5-4). Also, the ammeter LED for the corresponding unit of measure (S, %) of the active parameter will be illuminated. See Section 5-13 for all Adjust parameter ranges.
5-12. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) 1 1 3 2 3 1.0 SPO Spot Time Meter Display Select Spot function according to Section 6-3G. 2 Amperage Switch Pad Encoder Control Set spot parameters as follows: Press Amperage switch pad once (meter A LED turns on) and turn Encoder to set spot amperage. Press Amperage switch pad again, (meter S LED lights) and turn Encoder to set spot time (.1−25 seconds). Factory default setting is 1 second. Application: To provide a timed weld.
ADJUST *PREFLOW 0.2 S 0.0 − 25.0 Seconds POST FLOW 10.0 S 0.0 − 50.0 Seconds @ 0.2 Second Resolution DIG 30% 0 − 100 Percent .094 GEN, .020, .040, .062, .094, .125 ***Amperage 60 1 − 200 Amps ***Time 1 1 − 200 Milliseconds ***Start Slope Time 40 0 − 250 Milliseconds ***Preset Amperage Minimum 3 1 − 20 Amps MAXSTAR: *Tungsten * Parameter adjusted using an Advanced Functions configuration only (see Section 6). ** Parameter used with the automation option (LX models only).
5-15.
SECTION 6 − ADVANCED FUNCTIONS 6-1. Accessing Advanced Functions 3 1 2 1 2 3 Amperage Switch Pad Adjust Encoder Control To access the advanced functions, press and hold the Amperage (A) switch pad and then press the Adjust switch pad. To scroll through the advanced functions, press and release the Adjust switch pad. Use the Encoder control to change parameters for each function. starts for different tungstens.
6-2. Programmable TIG Start Parameters A. Tungsten Selection 3 2 tun 094 1 Current (A) Start Amperage Preset Amperage Minimum Start Time Start Slope Time 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter OM-2226 Page 40 Preset TIG Start Parameters Use Encoder control to select a tungsten size from the following: .020, .040, .062 (1/16 in.), .094 (3/32 in.), or .125 (1/8 in.) (.094 is the default).
B. Selecting GEN 1 2 3 2 1 GEn 3 Encoder Control Amps Meter Amperage Switch Pad If [GEn] is selected and displayed on the amps meter, the TIG starting parameters for a .094 tungsten are the default: Start Amperage = 60 A, Start Time = 1 ms, Start Slope Time = 40 ms, Preset Minimum Amps = 3 A. These parameters can be manually changed by pressing the Amperage switch pad to step through each adjustable parameter. To change parameters, see Sections C, D, E, and F.
C. Changing Programmable TIG Start Amperage 3 2 StA 20 1 Current (A) Start Amperage 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Amperage proceed as follows: Press Amperage switch pad. Switch pad LED turns on, and meter A LED turns on. The current Start Amperage is displayed on the amps meter, and can be adjusted (see Section 5-13) by turning the Encoder control. To change Start Time, proceed to Section D. D.
E. Changing Start Slope Time 3 2 StS 20 1 Current (A) Start Slope Time 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter F. To adjust Start Slope Time proceed as follows: Press Amperage switch pad. Switch pad LED turns on, and meter S LED turns on. The Start Slope Time is displayed in milli- seconds on the amps meter, and can be adjusted (see Section 5-13) by turning the Encoder control. To change Preset Amperage Minimum, proceed to Section F.
6-3. Output Control And Trigger Functions A. Remote (Standard) Torch Trigger Operation Current (A) Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow P&H R R Maintained Switch Foot Or Finger Remote Control P&H = Push trigger and hold R = Release trigger. . When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope and final amps are controlled by the remote control, not by the welding power source. B.
C. 3T Specific Trigger Method 1 2 3t rt = 3T Current (A) Remote Trigger Operation * * * A Preflow * * * * B Initial Amps /Initial Slope C Main Amps D Final Slope /Final Amps E Postflow * Arc can be extinguished at any time by pressing and releasing both initial and final switches, or by lifting the torch and breaking the arc. 1 3T (Specific Trigger Operation) Sequencer is required to reconfigure for 3T.
D. 4T Specific Trigger Method 2 1 1 2 4T (Specific Trigger Operation) Encoder Control To select 4T, turn Encoder control. 4t rt Torch trigger operation is as shown. 4T allows the operator to toggle between weld current and final current. = 4T . When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source.
F. 4T Momentary Operation 1 2 4T Momentary Meter Display Encoder Control To select 4T Momentary, turn Encoder control. 4T Momentary torch trigger operation is as shown. . When a remote switch is connected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source. Application: Use 4T Momentary trigger method when the functions of a remote current control are desired, but only a remote on/off control is available.
G. Spot Control Operation 1 Spot Function Meter Display . While in Spot Control, Sequencer settings will be ignored and will not be programmable. . When a remote switch is con- nected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source. Torch trigger operation is as shown. Application: To provide a timed weld. Used for tacking, and thin sheet joining.
H.
6-4. Setting Preflow Time 1 1 PrE Encoder Control Turn encoder to select from 0 to 25 seconds of preflow. The value selected is displayed on the ammeter. Application: Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting. 0.2 6-5. Stick Open-Circuit Voltage (OCV) Selection 1 2 oc LO 1 Encoder Control played on the meters. 2 Meter Display When Stick low OCV is selected, open-circuit voltage is between 9 and 14 volts.
6-7. Lockout Functions A. Accessing Lockout Capability Toggle 1 2 Loc oFF Select Lockout Level 1, 2, 3, or 4 Toggle cod oFF Select Code Number 1 to 999 See Section 5 for explanation of controls referred to in all of Section 6-7. thru [999]. IMPORTANT: remember this code number, as you will need it to turn the lockout feature off. There are four (1−4) different lockout levels. Each successive level allows the operator more flexibility. Toggle Amperage (A) switch pad until lock is displayed.
B. Lockout Levels Levels 1, 2, And 3 L3 Use Encoder Control To Adjust Amperage ±10% Of Preset Value. Indicates which functions are available for the corresponding lockout level. L2 L1 L3 Level 4 A B K J I H C L N D M G E F . Before activating lockout levels, be sure that all procedures and parameters are established. Parameter adjustment is limited while lockout levels are active. Level 1 ited by lock level 1, [LOCK][LEV1] is displayed as a reminder. Level 2 .
6-8. Setting Unit To Display PPP While Pulse Welding (DX Models Only) 2 Encoder Control 2 PPP Meter Display Turn Encoder to change between standard and [PPP] meter display. PPP 1 PLS 1 When the [PPP] meter display feature is active while pulse welding, the [PPP] will be displayed on the right meter display, and the Meter Hold feature is disabled. The [PPP] meter display feature will not effect the normal amperage display or Meter Hold capabilities when in a non-pulse welding mode. −−− 6-9.
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. A. Welding Power Source n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Δ = Repair l = Replace Δ = Repair l = Replace Every 3 Months nl Labels n l Gas Hoses Every 3 Months nΔ lCables And Cords Every 6 Months ! Do not remove case when blowing out inside of unit (see Section 7-2) .
7-2. Blowing Out Inside Of Unit ! Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown.
7-3. Voltmeter/Ammeter Help Displays 0 V A HEL 1 P-0 V A HEL 2 3 4 HEL 5 HEL A 0 Indicates a short in the thermal protection circuitry located on the bottom heat sink. Contact a Factory Authorized Service Agent if this display is shown. 1 Help 1 Display Indicates a malfunction in the primary power circuit caused by an overcurrent condition in the primary IGBT switching circuit. Contact a Factory Authorized Service Agent if this display is shown.
7-4. Troubleshooting Trouble No weld output; unit completely inoperative. Remedy Place line disconnect switch in On position (see Section 4-16). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-16). Check for proper input power connections (see Section 4-16). No weld output; meter display On. If using remote control, be sure correct process is enabled to provide output control at Remote 14 receptacle (see Section 4-8 as applicable).
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1.
SECTION 9 − HIGH FREQUENCY (HF) 9-1. Welding Processes Requiring High Frequency 1 High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. 1 Work TIG 9-2.
SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING 10-1. DC - GTAW 16 Gauge Stainless Steel Set-Up Ammeter Encoder 207 690-A This symbol indicates which functions should be active for stainless steel.
SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2010-04 Whenever possible and practical, use DC weld output instead of AC weld output. 11-1.
SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) 12-1. Positioning The Torch ! Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using cerium or lanthanum based tungsten instead of thoriated. Thorium dust contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way.
12-2. Torch Movement During Welding Tungsten Without Filler Rod 75° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod 75° Welding direction Form pool 15° Tilt torch Remove rod Add filler metal Move torch to front of pool. Repeat process. ST-162 002-B 12-3.
SECTION 13 − SETUP GUIDE FOR (SMAW) STICK WELDING 13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 1 1 Front Panel Correct front panel display for basic Stick DCEP welding. . For all front panel switch pad controls: press switch pad to turn on light and enable function. . Gray on nameplate indicates a Stick function (see Section 5-1 for description of controls).
SECTION 14 − STICK WELDING (SMAW) GUIDELINES 14-1. Stick Welding Procedure ! Weld current starts when electrode touches workpiece. ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Equipment Needed: Tools Needed: . Always wear appropriate per1 Constant Current Welding Power Source sonal protective clothing. Workpiece Make sure workpiece is clean before welding.
6013 7014 7018 7024 Ni-Cl 308L ALL DEEP EP ALL DEEP 6013 EP,EN ALL LOW GENERAL 7014 EP,EN ALL MED 7018 EP ALL MED SMOOTH, EASY, FAST LOW HYDROGEN, STRONG 7024 EP,EN NI-CL EP FLAT HORIZ FILLET ALL 308L EP ALL USAGE EP 6011 AC PENETRATION 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 DC* 6010 ELECTRODE 450 400 350 300 AMPERAGE RA
14-4. Positioning Electrode Holder 1 2 End View Of Work Angle Side View Of Electrode Angle 1 10°-30° 90° 2 90° Groove Welds 10°-30° 45° 1 2 45° Fillet Welds S-0060 14-5. Poor Weld Bead Characteristics 1 2 3 4 5 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 4 2 3 5 1 S-0053-A 14-6. Good Weld Bead Characteristics 1 2 3 Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1/8 in. (3.
14-7. Conditions That Affect Weld Bead Shape . Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Angle Too Small Correct Angle 10° - 30° Angle Too Large Electrode Angle Drag Spatter Arc Length Too Short Normal Too Long Slow Normal Fast Travel Speed S-0061 14-8. Electrode Movement During Welding .
14-9. Groove (Butt) Joints 1 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 1 2 2 3 1/16 in. (1.6 mm) Square Groove Weld Good for materials up to 3/16 in. (5 mm) thick. Single V-Groove Weld Good for materials 3/16 − 3/4 in. (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.
14-12. Weld Test 1 2 3 Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 3 3 2 To 3 in. (51-76 mm) 1/4 in. (6.4 mm) 2 1 2 To 3 in. (51-76 mm) 2 1 S-0057-B 14-13. Troubleshooting Porosity − small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty.
Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Reduce travel speed.
Notes OM-2226 Page 73
SECTION 15 − PARTS LIST . Hardware is common and not available unless listed. 12 28 25 615 28 13 33 8 11 19 18 38 16 35 6 401 400 402 10 14 2 15 3 37 614 30 17 4 9 1 7 403 36 600 5 Figure 15-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-1. Main Assembly 1 . . . . . . . . . . . . . . . . . . Fig15-2 2 . . . . . . . . . . . . . . . . . . Fig15-3 3 . . . . . . . . . . . . . . . . . . Fig15-4 4 . . . . . . . . . . . . . . . . . . Fig15-5 5 . . . . . . . . . . . . . . . . . . Fig15-7 6 . . . . . . . . S1 . . . . . . 231191 7 . . . . . . . . . . . . . . . . . . 200393 8 . . . . . . . PM1 . . . . . . 204821 9 . . . . . . . . . . . . . . . . . . 049611 10 . . . . . . . . . . . . . .
400 604 . Hardware is common and not available unless listed. 1 7 3 603 4 17 5 14 6 13 12 2 602 9 11 8 15 16 805 151-C Figure 15-2. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Quantity 15-2. Panel, Front w/Components (Figure 15-1 Item 1) 1 . . . . . . . . . . . . . . . . . . 194242 . . . . Panel, Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . . . . . . . . . . . 195647 . . . .
. Hardware is common and not available unless listed. Ref. 199 492-C Figure 15-3.Panel, Rear w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-3. Panel, Rear w/Components (Figure 15-1 Item 2) 1 . . . . . . . . . . . . . . . . . . 194242 . . . . 2 . . . . . . . . . . . . . . . . . . 206053 . . . . 3 . . . . . . . . . . . . . . . . . . 195646 . . . . 3 . . . . . . . . . . . . . . . . . . 197127 . . . . 4 . . . . . . . . . . . . . . . . . . 201155 . . . . 5 . . . . . . . . . . .
. Hardware is common and not available unless listed. Figure 15-4. Magnetics Assembly w/Components Item No. Dia. Mkgs. Part No. Description 805 153-A Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) 1 .................. 2 .................. 3 . . . . . . . FM1 . . . . . . 4 . . . . . . . GS1 . . . . . . 5 .................. 6 . . . . . . . CR1 . . . . . . 7 .................. 8 . . . . . . . . Z1 . . . . . . 9 . . . . . . . . L2 . . . . . . 10 . . . . . . . L3 . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) (Continued) 600 603 609 611 614 617 ................ ................ ................ ................ ................ ................ 199538 057357 137761 231179 010381 170647 .... .... .... .... .... .... Grommet, Scr No 8/10 Panel Hole .281 Sq .250 High . . . . . . . . . . . . . . . Bushing, Snap−in Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . .
1 . Hardware is common and not available unless listed. 8 4 2 602 6 3 5 7 Figure 15-5. Windtunnel w/Components Ref. 199 494-F 10 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-5. Windtunnel w/Components (Figure 15-1 Item 4) 1 . . . . . . . . . . . . . . . . . . 195645 2 . . . . . . . . . . . . . . . . . . 198634 3 . . . . . . . . . . . . . . . . . . 198633 4 . . . . . . . . . . . . . . . . . . 232856 5 . . . . . . . . . . . . . . . . . . 198652 6 . . . . . . . . . . . . . . .
606 . Hardware is common and not available unless listed. 2 604 604 5 6 600 7 3 4 1 Figure 15-6. Heat Sink, Secondary Assembly Item No. Dia. Mkgs. Part No. Description 199 497-H Quantity Figure 15-6. Heat Sink, Secondary Assembly (Figure 15-5 Item 7) 1 . . . . . . . . . . . . . . . . . . 210783 . . . . Heat Sink, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . D1 . . . . . . 204820 . . . . Kit, Diode, Ultra Fast . . . . . . .
. Hardware is common and not available unless listed. Figure 15-7. Base Assembly Item No. Dia. Mkgs. Part No. Description 199 493-B Quantity Figure 15-7. Base Assembly (Figure 15-1 Item 5) 1 . . . . . . . . . . . . . . . . . . 195644 . . . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . . . . . . . . . . . 239388 . . . . Bumper, RBR .875 OD x .188 ID x .39 High Recessed . . . . . . . . . . . . . .
Notes OM-2226 Page 83
SECTION 16 − COOLER PARTS LIST . Hardware is common and not available unless listed. 11 10 13 3 12 2 7 16 7 18 15 14 19 1 8 13 6 6 9 17 5 22 7 4 21 15 20 25 23 19 24 26 27 28 805 266-A Figure 16-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 16-1. Main Assembly 1 . . . . . . . . . . . . . +235416 . . Wrapper, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 188980 . . Label, Caution Incorrect Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . . . . . . . . . . . . . . 203990 . . Label, Warning General Precautionary Static . . . . . . . . . . . . . . . . . . .
SECTION 17 − CART PARTS LIST . Hardware is common and not available unless listed. 17 7 1 . Item 4 can be mounted in 7 alternative position if desired. 3 4 17 5 16 6 12 2 8 9 10 9 15 14 6 11 12 13 805 337-B Figure 17-1. Cart Main Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 17-1. Cart Main Assembly 1 . . . . . . . . . . . . . . . . . . 235507 2 . . . . . . . . . . . . . . . . . . 227147 3 . . . . . . . . . . . . . . . . . +237593 4 . . . . . . . . . . . . . . .
Effective January 1, 2010 (Equipment with a serial number preface of MA or newer) 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.
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 Miller Electric Mfg. Co.
