OM-2226 189783T August 2004 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 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 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3.
TABLE OF CONTENTS SECTION 6 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Programable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Arc Timer/Counter Display . . . . . . . . . . . . .
Declaration of Conformity For European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit.) Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W.
Notes
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. 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. 1-2.
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. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. 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. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie « NOTA » ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance.
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées. Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. D Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLOSION LES ORGANES MOBILES peuvent causer des blessures. D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle. D Se tenir à l’écart des organes mobiles comme les ventilateurs. D Maintenir fermés et bien fixés les portes, panneaux, recouvrements et dispositifs de protection. D Ne pas installer l’appareil à proximité de produits inflammables.
2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.
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 3.2 1.3 Disconnect input plug or power before working on machine. 1 1.1 2 2.1 3 3.1 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 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.
3-2. Manufacturer’s Rating Label . See Section 4-4 for location. . Use rating label to determine input power requirements.
3-3.
SECTION 4 − INSTALLATION 4-1.
4-2. 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 100 Volts TIG Max 80 60 40 Stick/TIG Min DIG .
4-3. 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. Y Exceeding duty cycle can damage unit and void warranty.
4-4. Selecting A Location 1 2 3 Dimensions And Weight 34.7 lb (15.7 kg) - without power cord 37.3 lb (16.9 kg) - with power cord Identification Plate Rating Label Line Disconnect Device Locate unit near correct input power supply. Y 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) 1 SERIAL NO. Location And Airflow 3 STOCK NO.
4-5. Weld Output Terminals And Selecting Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding Y Turn off power before connecting to weld output terminals. Y Do not use worn, damaged, undersized, or poorly spliced cables.
4-7. Automation 10-Pin Connection (LX Models) Socket F 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 E G D J H Socket Information For 10-Pin Receptacle RC2 C I A B Ref. ST-802 458 Definitions Of Inputs And Outputs Inputs A - Closure to D starts the weld cycle. Opening closure stops weld cycle.
4-8. 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 4-9.
4-10. Stick DCEP (Direct Current Electrode Positive) Connections Y 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 4-6). 2 3 1 Ref. ST-802 471 4-11.
4-12. Connecting Input Power A. Connecting Three-Phase Input Power Y Installation must meet all National and Local Codes − have only qualified persons make this installation. 3 Y Disconnect and lockout/tagout input power before connecting input conductors from unit. = GND/PE Earth Ground 4 Y Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. .
B. Connecting Single-Phase Input Power Y Installation must meet all National and Local Codes − have only qualified persons make this installation. Y Disconnect and lockout/tagout input power before connecting input conductors from unit. Y Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. 1 8 . The Auto-Line circuitry in this unit au- =GND/PE Earth Ground tomatically adapts the power source to the primary voltage being applied.
Notes OM-2226 Page 23
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. NOTE: 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 7 Adjust Controls 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 See Section 5-16 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 Or A (Amperage Control) Encoder Control Ammeter Or 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. Polarity Control (Dynastyt Models Only) 1 Polarity Control Press switch pad until desired LED is illuminated. DC - Machine is set to DCEN (direct current electrode negative) for TIG welding, and to DCEP (direct current electrode positive) for Stick welding.
5-7. 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 11-3) arc starting method is activated. This method can be used with either AC or DC TIG welding. Make connections according to Section 4-9. 1 TIG Lift-Arct - When selected, is an arc starting method in which the electrode must come in contact with the workpiece to initiate an arc (see Section 11-3).
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 5-7) 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, LX And All CE Models) 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 5-7) 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 5-16 for all Adjust parameter ranges.
5-12. AC Waveshape (Dynasty Models Only) 1 2 3 3 AC Waveshape Encoder Control Ammeter Turn encoder (see Section 5-2) to set appropriate value for active AC Waveshape parameter. Value selected is shown on the ammeter (see Section 5-4). 2 See Section 5-16 for all AC Waveshape parameter ranges. Balance: AC Balance Control is enabled only if AC TIG process is selected. Use control to set percentage of time polarity is electrode negative.
5-14.
5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control On The Front Panel 4 SEL 0.2 2 1 And 3 V Or Rear Panel 1 Process Control Pad 2 Adjust Control Pad 3 Power Switch To adjust preflow, turn power switch on, and then press the Process and Adjust switch pads before the software version clears the meters, and hold the switch pads until software version clears the meters.
5-16. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution MEMORY 1 1−4 PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick ** Stick OCV Low OCV Low OCV / Normal OCV OUTPUT RMT STD RMT STD / RMT 2T / ON **RMT 2T 2T RMT 2T can be reconfigured for: 2T / 4T / Mini Logic / 4T Momentary / Spot (see Section 6-2C) A MAIN / PEAK DC TIG 150 A 1 − 200 Amps DC STICK 110 A 1 − 200 Amps Spot Time 1.0 S 0.1 − 25.
5-17. Resetting Unit To Factory Default Settings (All Models) 1 2 3 4 Process Switch Pad Output Switch Pad Adjust Switch Pad Power Switch To reset all welding power source functions to original factory settings, lockout feature must be off (see Section 6-4). Next turn power on, then press the Process, Output, and Adjust switch pads before the software version clears the meters, and hold the switch pads until software version clears the meters.
SECTION 6 − ADVANCED FUNCTIONS 6-1. Programable TIG Start Parameters A. Accessing Programmable TIG Start Parameters 4 2 Or 5 1 6 Or 3 And V Or Rear Panel NOTE: The welding cycle can be executed while in programmable start mode. Before accessing programmable TIG Start Polarity, Amperage, and Time modes, be sure that all procedures and parameters are established.
B. Changing Programmable TIG Start Polarity (Dynasty Models Only) 3 SEL 2 E− Or Or 1 C. 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Polarity proceed as follows: Press Amperage switch pad. Switch pad LED turns on, and meter % LED turns on. The current Start Polarity, (SEL] [E−] or [SEL] [EP] is displayed on meters, and can be adjusted (see Section 5-16) by turning the Encoder control. To change Start Amperage, proceed to Section C.
D. Changing Programmable Start Time (All Models) 3 SEL 2 10 Or Or 1 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter OM-2226 Page 38 To adjust Programmable Start Time proceed as follows: Press Amperage switch pad, and meter S LED turns on. The current Start Time is displayed on the amps meter, and can be adjusted by turning the Encoder control (see Section 5-16).
6-2. 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. NOTE: 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.
C. Reconfiguring RMT 2T HOLD For 2T, 3T, Spot, 4T, 4T Momentary, Or Mini Logic Control 4 SEL H−2 Or Or 1 2 3 And V Or Rear Panel For RMT STD (Remote Standard), RMT 2T Hold (Remote 2T Hold), and On trigger operation, see Section 6-2A, B, and H. 1 Process Switch Pad 2 Output Switch Pad 3 Power Switch OM-2226 Page 40 To access the RMT 2T HOLD reconfiguration screen, turn power switch on and then press the Process and Output switch pads before the software version clears the meters.
SEL SEL H−2 SPO = 2T (See Section 6-2B for operation) = Spot (See Section 6-2G for operation) 5 SEL H−4 SEL H4L SEL H4E = 4T Momentary SEL H-3 = 3T = 4T (DX, LX and CE Models) (See Section 6-2D for operation) = Mini Logic (DX, LX and CE Models) (See Section 6-2E for operation) (DX, LX and CE Models) (See Section 6-2F for operation) (DX, LX and CE Models) (See Section 6-2I for operation) OM-2226 Page 41
D. 4T Specific Trigger Method (DX, LX And All CE Models) 1 1 4T (Specific Trigger Operation) Sequencer is required to reconfigure for 4T. SEL Select 4T according to Section 6-2C. H−4 Torch trigger operation is as shown. = 4T 4T allows the operator to toggle between weld current and final current without breaking the arc. NOTE: 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.
E. Mini Logic Operation (DX, LX And All CE Models) 1 1 Mini Logic Meter Display Select Mini Logic according to Section 6-2C. Torch trigger operation is as shown. SEL H4L = While in mini logic, the operator may use the trigger on the remote device to toggle between initial slope or main amps and initial amps as illustrated. Mini Logic During Mini Logic, Final Amperage is not available. Final slope will always slope to minimum amperage and end the cycle.
F. 4T Momentary Operation (DX, LX And All CE Models) 1 4T Momentary Meter Display Select 4T Momentary according to Section 6-2C. 4T Momentary torch trigger operation is as shown. 1 SEL H4E = NOTE: 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.
G. Spot Control Operation 1 1 SEL Spot Function Meter Display Select Spot function according to Section 6-2C. NOTE: While in Spot Control, Sequencer settings will be ignored and will not be programmable. SPO = Spot NOTE: 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. Torch trigger operation is as shown. Application: To provide a timed weld. Used for tacking, and thin sheet joining.
H.
3T Specific Trigger Method (DX, LX And All CE Models) I. 1 SEL H-3 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. 3T requires two independent momentarycontact switches.
6-3.
6-4. Lockout Functions A. Accessing Lockout Capability 4 5 LL−0 −− 000 1 6 And 000 LL−0 L1 or 2,3,4 3 2 V Or Rear Panel See Section 5-1 for explanation of controls referred to in all of Section 6-4. Toggle Amperage (A) switch pad to light the meter S LED. You may now select a lockout level. There are four (1−4) different lockout levels. Each successive level allows the operator more flexibility. There are four lockout levels available.
B. LockOut Levels Level 1 NOTE: Before activating lock out levels, be sure that all procedures and parameters are established. Parameter adjustment is limited while lock out levels are active. Level 1 NOTE: Remote amperage control is not available in level 1.
B. Lock Out Levels (Continued) Level 3 Level 3 NOTE: Remote amperage control is not available in level 3. Use Encoder Control To Adjust Amperage +/− 10% Of Preset Value. Includes all the functions of levels 1 and 2 plus the following: +/− 10% adjustment of preset TIG or Stick Weld Amps Select desired process, TIG or Stick, and use Encoder control to adjust amperage +/− 10% of preset amperage value, up to the limits of the machine.
6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only) 5 PPP 4 sel −−− 2 1 3 And V Or Rear Panel 1 Output Switch Pad 2 Pulser Switch Pad 3 Power Switch To access the PPP while welding display, turn power switch on, and then press the Output and Pulser switch pads before the software version OM-2226 Page 52 clears the meters. Hold the switch pads until [SEL] [−−−] or [SEL] [PPP] appears.
6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models) 5 6 sel loc 3 2 1 4 And V Or Rear Panel 1 Process Switch Pad 2 Adjust Switch Pad 3 Amperage Switch Pad 4 Power Switch To access the Stick OCV selection, turn power switch on and then press the Process, Adjust and Amperage switch pads before the software ver- sion clears the meters. Hold the switch pads until [SEL] [Loc] or [SEL] [noc) appears.
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Replace Damaged Gas Hose 3 Months Repair Or Replace Cracked Cables And Cords 6 Months Y Do not remove case when blowing out inside of unit (see Section 7-2) . Blow out inside. During heavy service clean monthly. 7-2.
7-3. Voltmeter/Ammeter Help Displays V A 0 HEL V P−0 V HEL P−1 V P−2 V HEL P−3 V A 4 HEL V A HEL P−8 V A 7 HEL A 3 P−5 6 A 2 HEL HEL A 1 A 5 V P−9 A 8 HEL V P10 A 9 P−4 HEL P12 V A 10 HEL . All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. 0 Help 0 Display Indicates a short in the thermal protection circuitry located on the bottom heat sink.
7-4. Troubleshooting Trouble No weld output; unit completely inoperative. Remedy Place line disconnect switch in On position (see Section 4-12). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12). Check for proper input power connections (see Section 4-12). 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 4-6 as applicable).
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 − SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw 7/97 NOTE For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent contamination of tungsten electrode. 10-1.
10-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding 1 1 2 2 Tungsten Electrode Tapered End Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality. 2-1/2 Times Electrode Diameter 1 2 1 2 Diameter of this flat determines amperage capacity. 3 3 Stable Arc Flat Grinding Wheel Grinding wheel should be dedicated to grinding tungsten only.
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) 11-1. DC - GTAW 16 Gauge Stainless Steel Set-Up Ammeter Encoder 207 690-A This symbol indicates which functions should be active for stainless steel.
11-2. Positioning The Torch 3 2 4 90° 1 Y 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. Wear proper face, hand, and body protection.
11-3. 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.
11-4. 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 Tilt torch Remove rod 15° Add filler metal Move torch to front of pool. Repeat process.
11-5.
SECTION 12 − STICK WELDING (SMAW) GUIDELINES 12-1. 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. NOTE: Gray on nameplate indicates a Stick function (see Section 5-1 for description of controls).
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 LOW SMOOTH, EASY, FAST LOW HYDROGEN, STRONG 7024 EP,EN NI-CL EP FLAT HORIZ FILLET ALL 308L EP ALL USAGE PENETRATION EP 6011 AC 6010 DC* 450 400 350 300 AMPERAGE RANGE 250 200 150 POSITION 6013 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/
12-3. Stick Welding Procedure Y Weld current starts when electrode touches workpiece. 5 Y 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. 4 2 1 Workpiece Make sure workpiece is clean before welding. 2 3 3 A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 12-2).
12-6. Positioning Electrode Holder 10°-30° 90° 90° End View of Work Angle Side View of Electrode Angle GROOVE WELDS 10°-30° 45° 45° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 12-7. Poor Weld Bead Characteristics 1 2 3 4 5 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 1 2 4 3 5 S-0053-A 12-8.
12-9. Conditions That Affect Weld Bead Shape NOTE 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 Drag ELECTRODE ANGLE Spatter Normal Too Short Too Long ARC LENGTH Normal Slow Fast TRAVEL SPEED S-0061 12-10.
12-11. Butt Joints 1 1 2 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 1/16 in (1.6 mm) 30° Single V-Groove Weld Good for materials 3/16 − 3/8 in (5-9 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.
12-14. Weld Test 1 2 3 3 Strike weld joint in direction shown. A good weld bends over but does not break. 3 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) Vise Weld Joint Hammer 2 To 3 in (51-76 mm) 2 2 1 1 S-0057-B 12-15. Troubleshooting − Porosity 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.
12-17. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding. Adjust work angle or widen groove to access bottom during welding.
12-20. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Excessive heat input. Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 12-21. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. Possible Causes Unsteady hand. Corrective Actions Use two hands.
Notes OM-2226 Page 75
SECTION 13 − PARTS LIST . Hardware is common and not available unless listed. 12 29 25 615 13 8 33 28 11 19 6 18 16 401 400 402 10 14 GROUND STUD DETAIL 31 2 15 3 30 614 17 4 9 7 1 403 32 5 600 Figure 13-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-1. Main Assembly 1 . . . . . . . . . . . . . . . . . . Fig13-2 2 . . . . . . . . . . . . . . . . . . Fig13-3 3 . . . . . . . . . . . . . . . . . . Fig13-4 4 . . . . . . . . . . . . . . . . . . Fig13-5 5 . . . . . . . . . . . . . . . . . . Fig13-7 6 . . . . . . . . S1 . . . . . . 128756 7 . . . . . . . . . . . . . . . . . . 200393 8 . . . . . . . PM1 . . . . . . 204821 9 . . . . . . . . . . . . . . . . . . 049611 10 . . . . . . . . . . . . . .
. Hardware is common and not available unless listed. Figure 13-2. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Ref. 199 491-A Quantity 13-2. Panel, Front w/Components (Figure 13-1 Item 1) 1 .................. 2 .................. 3 .................. 3 .................. 3 .................. 3 .................. 4 .................. 5 .................. 6 .................. 6 .................. 6 .................. 7 . . . . . . . RC1 . . . . . . 8 .................. 9 .......
Item No. Dia. Mkgs. Part No. Description Quantity 13-2. Panel, Front w/Components (Figure 13-1 Item 1) (continued) 601 . . . . . . . . . . . . . . . . 106702 . . . . Nut, 006−32 .31hex .20hex .20h Stl Pld (CE Models Only) . . . . . . . . . . 4 602 . . . . . . . . . . . . . . . . 166560 . . . . Ring, Rtng Ext .500 Shaft X .042 Thk E Style Bowed . . . . . . . . . . . . . . . 1 603 . . . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and not available unless listed. Ref. 199 492-A Figure 13-3.Panel, Rear w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-3. Panel, Rear w/Components (Figure 13-1 Item 2) 1 . . . . . . . . . . . . . . . . . . 194242 2 . . . . . . . . . . . . . . . . . . 206053 3 . . . . . . . . . . . . . . . . . . 195646 3 . . . . . . . . . . . . . . . . . . 197127 4 . . . . . . . . . . . . . . . . . . 186440 4 . . . . . . . . . . . . . . . . . . 201155 5 . . . . . . . .
. Hardware 603 is common and not available unless listed. 604 613 613 609 3 5 17 7 21 603 13 14 15 4 10 12 9 12 5 1 14 611 13 603 604 600 614 2 400 612 8 11 6 Ref. 199 501-J Figure 13-4. Magnetics Assembly w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-4. Magnetics Assembly w/Components (Figure 13-1 Item 3) 1 .................. 2 .................. 3 . . . . . . . FM1 . . . . . . 4 . . . . . . . GS1 . . . . . . 5 .................. 6 . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-4. Magnetics Assembly w/Components (Figure 13-1 Item 3) (Continued) 603 604 609 611 612 613 614 ................ ................ ................ ................ ................ ................ ................ 057357 182737 137761 136343 099273 083147 010381 .... .... .... .... .... .... .... Bushing, Snap−in Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . . Screw, 010−32x2.00 Rnd Hd−slt Brs Pln . . . . . . . . . .
. Hardware is common and not available unless listed. Ref. 199 494 Figure 13-5. Windtunnel w/Components 10 Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-5. Windtunnel w/Components (Figure 13-1 Item 4) 1 . . . . . . . . . . . . . . . . . . 195645 2 . . . . . . . . . . . . . . . . . . 198634 3 . . . . . . . . . . . . . . . . . . 198633 4 . . . . . . . . . . . . . . . . . . 189777 5 . . . . . . . . . . . . . . . . . . 198652 6 . . . . . . . . . . . . . . . . . +192450 7 . . . . . . . .
. Hardware is common and not available unless listed. 199 497-C Figure 13-6. Heat Sink, Secondary Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-6. Heat Sink, Secondary Assembly (Figure 13-5 Item 7) 1 . . . . . . . . . . . . . . . . . . 210783 . . . . Heat Sink, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . D1 . . . . . . 204820 . . . . Kit, Diode, Ultra Fast . . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and not available unless listed. 199 493-B Figure 13-7. Base Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 13-7. Base Assembly (Figure 13-1 Item 5) 1 . . . . . . . . . . . . . . . . . . 195644 . . . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . . . . . . . . . . . 019663 . . . . Mount, Nprn 15/16odx3/8rec 3/16x3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes
Effective January 1, 2004 (Equipment with a serial number preface of “LE” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. 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.
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 Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number.
