OM-2226 189783G April 2002 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 WARNING This product, when used for welding or cutting, 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.) The following terms are used interchangeably throughout this manual: TIG = GTAW Stick = SMAW SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION 5 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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. 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 electromagnetic fields. There has been and still is some concern about such fields.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D Rester à l’écart des organes mobiles comme le ventilateur. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W.
SECTION 2 – DEFINITIONS (CE Models) 2-1. 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.
2-2. Manufacturer’s Rating Label . See Section 3-4 for location. . Use rating label to determine input power requirements.
2-3.
SECTION 3 – INSTALLATION 3-1. Specifications Amperes Input At Rated Output, 50/60Hz Welding Amperage Range Max. Open-Circuit Voltage 150 A @ 26 VDC, 60% Duty Cycle 1 – 200 9-14♦ TIG Process 175 A @ 17 VDC, 60% Duty Cycle 1 – 200 9-14♦ Three-Phase Stick Process 200 A @ 28 VDC, 30% Duty Cycle 1 – 200 80 18.4 10.3 8.9 7.3 7.0 9-14♦ 0.16* 0.24* 0.25* 0.06* 0.03* Three-Phase TIG Process 200 A @ 18 VDC, 40% Duty Cycle 1 – 200 80 12.7 7.2 6.2 5.1 4.9 9-14♦ 0.16* 0.24* 0.25* 0.
3-2. 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. Volts 115VAC Input 140 120 100 80 60 40 20 0 Stick Max. TIG Max. Stick/TIG Min. DIG Max. 0 50 100 150 200 250 Amperes Volts Other Input Voltages 140 120 100 80 60 40 20 0 Stick Max. TIG Max. Stick/TIG Min. 0 50 DIG Max.
3-3. 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 5-3), 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.
3-4. 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.
3-5. 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.
3-7. 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.
3-8. 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 3-9.
3-10. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) 1 Front Panel Correct front panel display for basic TIG HF Impulse DCEN welding. . 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 (see Section 4-1 for description of controls).
3-11. 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 3-6). 2 3 1 Ref.
3-12. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 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 4-1 for description of controls).
3-13. Electrical Service Guide NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, no output is available. Input Voltage Input Amperes At Rated Output Single-Phase, 100% Duty Cycle Single-Phase, 60% Duty Cycle 115 230 230 400 460 25 22 13.1 7.4 6.
3-14. Connecting Input Power Y Disconnect and lockout/tagout input power before connecting input conductors from unit. Y Have only qualified persons make this installation. Check input voltage available at site. 3 1 2 1 Green Or Green/Yellow Line Disconnect Device Input And Grounding Conductors See Section 3-13. For three-phase operation: Y Always connect green or green/yellow wire to supply grounding terminal, never to a line terminal.
SECTION 4 – OPERATION 4-1. Controls A. Non CE Units (DX/LX Model Shown) 3 1 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 4-2. 2 Parameter Display See Section 4-3. 3 Voltmeter See Section 4-3.
B. For CE Units (DX/LX Model Shown) 3 1 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 4-2. 2 Parameter Display See Section 4-3. 3 Voltmeter See Section 4-3. 4 Process Controls See Section 4-4.
4-2. Encoder Control 1 Encoder Control Use control in conjunction with applicable front panel function switch pad to set values for that function. 1 4-3. Ammeter And Volt Meter 1 1 2 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. 2 Parameter Display Displays actual amperage while welding.
4-5. 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 with torch trigger, foot control, or hand control. Hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. Shielding gas begins to flow when electrode touches workpiece and arc is formed when electrode is lifted.
4-6. Stick Start Procedure – Scratch Start Technique With Stick selected, start arc as follows: 1 2 3 Electrode Workpiece Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it. 1 Normal open-circuit voltage is not present before electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece.
4-7. Output Control CE Models Only 1 1 Output Control Press switch pad until desired parameter LED is illuminated. RMT STD (Remote Standard) Torch trigger operation is as shown. NOTE: When a foot or finger remote control is connected to the welding power source, initial amps, initial slope, final slope, and final amps are not functional.
1 Output Control Press switch pad until desired parameter LED is illuminated. RMT 2T Hold Press switch pad to activate function. Torch trigger operation is as shown. NOTE: A foot or finger remote control must be connected to the welding power source, only trigger input is functional. welding power source. NOTE: Switch function can be reconfigured for 4T, 4TE, Mini Logic, or Spot control (see Section 4-14). Application: Use Remote Trigger Hold (2T) when long extended welds are made.
4-8. Amperage Control 1 2 3 3 2 1 CE Models Only 3 2 1 OM-2226 Page 32 A (Amperage Control) Encoder Control Parameter Display Press Amperage switch pad, and turn Encoder control to set weld amperage (1-200 amps). Weld amperage setting is also peak amperage when Pulser function is active (see Section 4-10). Amperage selected is displayed on the parameter display (see Section 4-3) and the A LED will be illuminated.
4-9. Adjust Controls (Post Flow/DIG) 1 Post Flow/DIG Control Press switch pad until desired function LED is illuminated. 3 2 2 Encoder Control 3 Parameter Display Post Flow - If the TIG process is active (see Section 4-4), press switch pad and turn encoder control to set length of time (0–50 seconds) gas flows after welding stops. Time selected is displayed (see Section 4-3) and the S LED will be illuminated.
4-10. Pulser Control (DX And LX Models) 1 3 2 CE Models Only Pulser Control If the Pulser is off, pressing the switch pad will enable the pulser, and place it in the PPS (Pulses Per Second) mode and illuminate the On and PPS LEDs. Pressing the switch again, will first place it in the Peak Time mode, and then in the Background Amperage Mode and illuminate the corresponding LED. If you cycle past Background Amps, the Pulser will shut off and default to the Main/Peak Amperage control.
4-11. Sequencer Controls (DX, LX And All CE Models) 1 Sequencer Control Press switch pad until desired parameter LED is illuminated. Sequencing is available only while using the TIG process, but is disabled if a remote foot or finger control is connected to the Remote receptacle (see Section 3-6). Sequencer parameters cannot be selected if the Stick process (see Section 4-4) is active.
4-12. Preflow Adjust (All Models) Non CE Models Only sel 4 00.2 2 1 3 And Rear Panel 1 Process Control Pad 2 Adjust Control Pad 3 Power Switch To adjust preflow, turn power off, push and hold Process and Adjust control switch pads, and turn On Power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears meters). OM-2226 Page 36 Upon power up as described, the TIG HF Impulse, Postflow, DIG, and meter S LED will turn on, and [SEL] [0.
CE Models Only SEL 4 00.2 2 3 1 And Rear Panel 1 2 3 Process Control Pad Adjust Control Pad Power Switch To adjust preflow, turn Off power. Push and hold Process and Adjust control switch pads, and turn On Power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears meters). Upon power up as described, the TIG Impulse, Postflow, DIG, and meter S LED will turn on, and [SEL] [0.2] will be displayed. 0.
4-13. Programmable TIG HF Impulse Start Amperage And Time Modes A. Accessing Programmable TIG Start Amperage And Time Modes (All Models) Non CE Models Only 1 1 2 And Rear Panel NOTE: Before accessing programmable TIG HF Impulse Start Amperage and Time modes, be sure that all procedures and parameters are established. Especially, check for proper amperage setting (see Section 4-8).
CE Models Only 1 1 2 And Rear Panel NOTE: Before accessing programmable TIG HF Impulse Start Amperage and Time modes, be sure that all procedures and parameters are established. Especially, check for proper amperage setting (see Section 4-8). Parameter adjustment is limited while programmable TIG HF Impulse Start Amperage and Time modes are active. 1 Process And Amperage Key Pads 2 Power Switch turn Off power. Push and hold Process and Amperage switch pads and turn On power switch.
B. Setting Programmable TIG Impulse Start Amperage (All Models) Non CE Models Only SEL 25 2 1 NOTE: Before accessing programmable TIG HF Impulse Start Amperage mode, be sure that all procedures and parameters are established. Especially, check for proper amperage setting (see Section 4-8). Parameter adjustment is limited while programmable TIG Impulse Start Amperage mode is active.
CE Models Only SEL 25 2 1 NOTE: Before accessing programmable TIG Impulse Start Amperage mode, be sure that all procedures and parameters are established. Especially, check for proper amperage setting (see Section 4-8). Parameter adjustment is limited while programmable TIG Impulse Start Amperage mode is active. Welding cycle can be executed while in programmable start mode, but program parameters cannot be adjusted while in this mode.
C. Setting Programmable Start Time (All Models) Non CE Models Only SEL 1 2 1 NOTE: Before accessing programmable start time mode, be sure that all procedures and parameters are established. Especially, check for proper amperage setting (see Section 4-8). Parameter adjustment is limited while Programmable Start Time mode is active. Welding cycle can be executed while in OM-2226 Page 42 programmable start mode, but program parameters cannot be adjusted while in this mode.
CE Models Only 1 SEL 2 1 NOTE: Before accessing programmable start time mode, be sure that all procedures and parameters are established. Especially, check for proper amperage setting (see Section 4-8). Parameter adjustment is limited while Programmable Start Time mode is active. Welding cycle can be executed while in programmable start mode, but program parameters cannot be adjusted while in this mode.
4-14. Reconfiguring 2T For 4T, 4T Momentary, Mini Logic Control, Or Spot (DX, LX And All CE Models) Non CE Models Only 4 SEL H-2 2 1 3 And Rear Panel 1 Process Switch Pad 2 Output Switch Pad 3 Power Switch To reconfigure 2T, turn power off. Push and hold the Process and Output switch pads and turn On power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and display reads [SEL] [H-2).
SEL H-2 SEL H-4 = 2T (See Section 4-7 for operation) = 4T (See Section 4-15 for operation) 5 SEL SEL SEL H4L H4E SPO = Mini Logic (See Section 4-16 for operation) = 4T Momentary (See Section 4-16 for operation) = Spot (See Section 4-17 for operation) OM-2226 Page 45
Reconfiguring 2T For 4T, 4T Momentary, Mini Logic Control, Or Spot (DX, LX And All CE Models) (Continued) CE Models Only 4 SEL H-2 2 1 And 3 V Rear Panel 1 Process Switch Pad 2 Output Switch Pad 3 Power Switch To reconfigure 2T, turn power off. Push and hold the Process and Output switch pads and turn On power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and display reads [SEL] [H-2].
SEL H-2 SEL H-4 = 2T (See Section 4-7 for operation) = 4T (See Section 4-15 for operation) 5 SEL H4L SEL H4E SEL SPO = Mini Logic (See Section 4-16 for operation) = 4T Momentary (See Section 4-16 for operation) = Spot (See Section 4-17 for operation) OM-2226 Page 47
4-15. 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 4-14. H-4 = 4T Torch trigger operation is as shown. While in 4T mode, there is a function available during the main weld sequence that allows the operator to toggle between weld current and final current without breaking the arc.
4-16. Mini Logic Operation (DX, LX And All CE Models) 1 1 Mini Logic Meter Display Sequencer option required to reconfigure for Mini Logic. SEL Select Mini Logic according to Section 4-14. H4L = Torch trigger operation is as shown. Mini Logic During Mini Logic welding operation, the weld current can be toggled between the initial amps level and the weld amps or slope level by pressing and releasing the torch trigger in less than 3/4 seconds. During Mini Logic, Final Amperage is not available.
4-17. Spot Control Operation (All Models) 1 1 Or SEL SPO Spot Function Display Select Spot function according to Section 4-14. 3 = 2 Spot 2 3 Amperage Switch Pad Encoder Control Set spot parameters as follows: Press Amperage switch pad once (A LED turns on) and turn Encoder to set spot amperage. 4 Spot Time Display Press Amperage switch pad again, (S LED lights) and turn Encoder to set spot time (.1–25 seconds). Factory default setting is 1 second.
4-18. 4T Momentary Operation (DX, LX And All CE Models) 1 4T Momentary Display Select 4T Momentary according to Section 4-14. 1 If unit is equipped with Sequence Controls, a 4T Momentary trigger method is available. 4T Momentary torch trigger operation is as shown. H4E SEL = 4T Momentary While in 4T Momentary mode, once the operator toggles out of weld current and begins final slope, toggling again will break the arc and go to postflow.
4-19. Arc Timer/Counter Display (All Models) Non CE Models 3/4 123 456 1 Or 1 2 V And Rear Panel 1 2 Output And Amperage Controls Power Switch To display the arc timer/counter, turn power off. Push and hold Output and Amperage control switch pads, and turn On Power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears displays).
CE Models 3/4 123 456 1 Or 1 2 V And Rear Panel 1 Output And Amperage Controls 2 Power Switch To display the arc timer/counter, turn power off. Push and hold Output and Amperage control switch pads, and turn On Power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears displays). 3 Arc Timer Display Upon power up as described above, the S LED will turn on, and arc time will be displayed for 5 seconds as [000 000] to [999 999).
4-20. Lockout Functions A. Accessing Lockout Capability 4 5 000 L– 1 6 000 And L L1 or 2,3,4 3 2 V Rear Panel See Section 4-1 for explanation of controls referred to in all of Section 4-20. Toggle Amperage (A) switch pad to light the 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 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. NOTE: Remote amperage control is not available in level 1.
C. Lockout Levels (Continued) Level 3 Level 3 Use Encoder Control To Adjust Amperage +/– 10% Of Preset Value. NOTE: Before activating lockout levels, be sure that all procedures and parameters are established. Parameter adjustment is limited while lockout levels are active. NOTE: Remote amperage control is not available in level 3.
4-21. 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, turn power off. Push and hold the Process, Output and Adjust switch pads and turn On power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears displays).
4-22. Setting Unit To Display PPP While Pulse Welding Non CE Models Only 5 PPP 4 sel --- 2 2 1 3 And Rear Panel 1 Output Switch Pad 2 Pulser Switch Pad 3 Power Switch Turn power off. Push and hold the Output and Pulser switch pads and turn On power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and meters display OM-2226 Page 58 [SEL] [Ć-- ).
CE Models Only 5 PPP 4 SEL --- 2 2 1 3 And Rear Panel 1 Output Switch Pad 2 Pulser Switch Pad 3 Power Switch Turn power off. Push and hold the Output and Pulser switch pads and turn On power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and meters display [SEL] [Ć-- ). Upon power up as described, the A LED under the right display and the Pulser On LED illuminate.
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING 5-1. 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 5-2) . Blow out inside. During heavy service clean monthly. 5-2.
5-3. 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.
5-4. Troubleshooting Trouble No weld output; unit completely inoperative. Remedy Place line disconnect switch in On position (see Section 3-14). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-14). Check for proper input power connections (see Section 3-14). 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 3-6 as applicable).
SECTION 6 – ELECTRICAL DIAGRAMS Figure 6-1.
SECTION 7 – HIGH FREQUENCY 7-1. 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 high_freq 12/96 – S-0693 7-2.
7-3. Correct Installation 7 Weld Zone 3 50 ft (15 m) 50 ft (15 m) 5 1 6 2 8 4 8 Ground all metal objects and all wiring in welding zone using #12 AWG wire. Nonmetal Building Ground workpiece if required by codes. 9 Metal Building 8 8 11 10 Ref. S-0695 / Ref. S-0695 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.
SECTION 8 – 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. 8-1.
8-3. 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 9 – GUIDELINES FOR TIG WELDING (GTAW) 9-1. 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.
9-2. 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 Tilt torch Remove rod 15° Add filler metal Move torch to front of pool. Repeat process.
9-3.
SECTION 10 – STICK WELDING (SMAW) GUIDELINES 10-1. Stick Welding Procedure Y Weld current starts when electrode touches workpiece. 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. 1 5 2 3 4 2 Work Clamp Electrode A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 10-2).
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 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* 450 400 350 300 AMPERAGE RANGE 250 200 150 POSI
10-5. 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 10-6. 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 10-7.
10-8. 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 10-9.
10-10. 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 – 3/4 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.
10-13. 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 10-14. 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.
10-16. 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.
10-19. 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. 10-20. 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 79
SECTION 11 – PARTS LIST . Hardware is common and not available unless listed. 12 29 25 615 13 8 28 11 6 19 18 16 401 400 402 14 10 GROUND STUD DETAIL (5) PLACES 3 31 2 30 614 17 4 9 7 1 32 601 5 600 15 Figure 11-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-1. Main Assembly 1 . . . . . . . . . . . . . . . . . . Fig11-2 2 . . . . . . . . . . . . . . . . . . Fig11-3 3 . . . . . . . . . . . . . . . . . . Fig11-4 4 . . . . . . . . . . . . . . . . . . Fig11-5 5 . . . . . . . . . . . . . . . . . . Fig11-7 6 . . . . . . . . S1 . . . . . . 128756 7 . . . . . . . . . . . . . . . . . . 200393 8 . . . . . . . PM1 . . . . . . 204821 9 . . . . . . . . . . . . . . . . . . 049611 10 . . . . . . . . . . . . . .
. Hardware is common and not available unless listed. Ref. 199 491-A Figure 11-2. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description Quantity 11-2. Panel, Front w/Components (Figure 11-1 Item 1) 1 . . . . . . . . . . . . . . . . . . 194242 2 . . . . . . . . . . . . . . . . . . 195647 3 . . . . . . . . . . . . . . . . . . 192884 3 . . . . . . . . . . . . . . . . . . 192886 3 . . . . . . . . . . . . . . . . . . 192888 3 . . . . . . . . . . . . . . . . . . 192890 4 . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity 11-2. Panel, Front w/Components (Figure 11-1 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 Figure 11-3.Panel, Rear w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-3. Panel, Rear w/Components (Figure 11-1 Item 2) 1 . . . . . . . . . . . . . . . . . . 194242 2 . . . . . . . . . . . . . . . . . . 195648 3 . . . . . . . . . . . . . . . . . . 195646 3 . . . . . . . . . . . . . . . . . . 197127 4 . . . . . . . . . . . . . . . . . . 186440 4 . . . . . . . . . . . . . . . . . . 201155 5 . . . . . . . . .
. Hardware is common and not available unless listed. Ref. 199 501 Figure 11-4. Magnetics Assembly w/Components Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-4. Magnetics Assembly w/Components (Figure 11-1 Item 3) 1 .................. 2 .................. 3 . . . . . . . FM1 . . . . . . 4 . . . . . . . GS1 . . . . . . 5 .................. 6 . . . . . . . CR1 . . . . . . 7 .................. 8 .................. 9 . . . . . . . . L2 . . . . . . 10 . . . . . . . L3 . . . . . . 11 . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-4. Magnetics Assembly w/Components (Figure 11-1 Item 3) (Continued) 603 604 609 611 612 613 614 617 ................ ................ ................ ................ ................ ................ ................ ................ 057357 182737 605227 136343 099273 083147 010381 181853 .... .... .... .... .... .... .... .... Bushing, Snap–in Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . . Screw, 010–32x2.
. Hardware is common and not available unless listed. Ref. 199 494 Figure 11-5. Windtunnel w/Components 10 Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-5. Windtunnel w/Components (Figure 11-1 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-B Figure 11-6. Heat Sink, Secondary Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-6. Heat Sink, Secondary Assembly (Figure 11-5 Item 7) 1 . . . . . . . . . . . . . . . . . . 206023 . . . . Heat Sink, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . D1 . . . . . . 204820 . . . . Kit, Diode, Ultra Fast . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and not available unless listed. 199 493 Figure 11-7. Base Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-7. Base Assembly (Figure 11-1 Item 5) 1 . . . . . . . . . . . . . . . . . . 195644 . . . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . . . . . . . . . . . 019663 . . . . Mount, Nprn 15/16odx3/8rec 3/16x3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Effective January 1, 2001 (Equipment with a serial number preface of “LB” 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.
