- Industrial & lab equipment
- Welding System
- Miller Electric
- SPOOLMATE 200 SK-200 Spot Panel
- Owner's manual
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OM-253 392D
Multiprocess Welding
Description
2012−08
Arc Welding Power Source
Wire Feeder
Multimatic 200
Visit our website at
www.MillerWelds.com
File: Multiprocess
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance.
And if for some reason the unit needs repair,
Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System
Standard.
there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem.
Warranty and service information for your particular model are also provided.
Working as hard as you do
− every power source from
Miller is backed by the most hassle-free warranty in the business.
Miller Electric manufactures a full line of welders and welding related equipment.
For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.
Mil_Thank 2009−09
TABLE OF CONTENTS
1-4. California Proposition 65 Warnings
1-5. Principal Safety Standards
2-4. Proposition californienne 65 Avertissements
2-5. Principales normes de sécurité
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM
3-2. Miscellaneous Symbols And Definitions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Specifications For TIG (GTAW)
4-3. Specifications For Stick (SMAW)
4-7. Duty Cycle And Overheating For Stick
5-1. Serial Number And Rating Label Location
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Connecting Shielding Gas Supply
6-9. Viewing Primary Power Information (Menu 6 Of 9)
6-10. Viewing Process Logs (Menu 7 Of 9)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
9-2. Typical MIG Process Control Settings
9-3. Holding And Positioning Welding Gun
9-5. Gun Movement During Welding
9-6. Poor Weld Bead Characteristics
9-11. Troubleshooting − Lack Of Penetration
9-12. Troubleshooting − Incomplete Fusion
SECTION 11 − SELECTING AND PREPARING A
11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
12-3. Positioning Torch Tungsten For Various Weld Joints
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
7
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
.
Indicates special instructions.
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. The possible hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.
The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.
D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
D Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly with a separate cable.
D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.
D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
D Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-253 392 Page 1
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.
D Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
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 an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks 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.
D Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards.
D Do not use welder to thaw frozen pipes.
OM-253 392 Page 2
D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.
D Wear approved safety glasses with side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
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.
D Use equipment of adequate capacity to lift and support unit.
D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling boards or parts.
D Use proper static-proof bags and boxes to store, move, or ship PC boards.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do so.
D Do not point gun toward any part of the body, other people, or any metal when threading welding wire.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local codes.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
D Have only qualified persons familiar with electronic equipment perform this installation.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots.
D Be sure all equipment in the welding area is electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive electronic equipment.
D Be sure this welding machine is installed and grounded according to this manual.
D If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.
OM-253 392 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
1-6. EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
OM-253 392 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
7 fre_som_2011−10
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
.
Indique des instructions spécifiques.
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. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures personnelles.
2-2. Dangers relatifs au soudage à l’arc
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger.
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Sec-
tion 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort.
Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.
D Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installez, mettez à la terre et utilisez correctement cet équipement conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé.
OM-253 392 Page 5
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.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intense
D Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
OM-253 392 Page 6
LE SOUDAGE peut provoquer un incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.
D Fermer l’alimentation du gaz comprimé 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.
D Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut affecter l’ouïe.
D Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3.
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et les yeux.
D Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
OM-253 392 Page 7
Les PIÈCES MOBILES peuvent causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement tels que des rouleaux de commande.
LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
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.
L’EXPLOSION DE LA BATTERIE peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage.
D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles.
Les PIÈCES MOBILES peuvent causer des blessures.
D S’abstenir de toucher des organes mobiles tels que des ventilateurs.
D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux.
2-4. Proposition californienne 65 Avertissements
LE SOUDAGE À L’ARC risque de provoquer des interférences.
D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation.
OM-253 392 Page 8
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage. Les CEM peuvent créer des interférences avec certains implants médicaux comme des stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: Limiter par exemple tout accès aux passants ou procéder à une évaluation des risques individuels pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre corps.
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
4. Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
OM-253 392 Page 9
OM-253 392 Page 10
SECTION 3 − DEFINITIONS
3-1. Manufacturer’s Warning Label Definitions
V
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe95 2012−05
Beware of electric shock from wiring.
Safe94 2012−08
When power is applied failed parts can explode or cause other parts to explode.
>5min
V
V
Safe26 2012−05
Become trained and read the instructions before working on the machine or welding.
Safe40 2012−05
Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. Always wait 5 minutes after power is turned off before working on unit, OR check input capacitor voltage, and be sure it is near 0 before touching any parts.
Safe43 2012−05
Notes
OM-253 392 Page 11
3-2. Miscellaneous Symbols And Definitions
A
Amperage
Direct Current
(DC)
Gas Input Circuit Breaker
I
2
U
1
Primary Voltage Positive
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert Gas
(TIG) Welding
U
2
Conventional
Load Voltage
IP
Internal Protection
Rating
U
0
Rated No Load
Voltage (Average)
Single Phase
Remote
Shielded Metal Arc
(SMAW) Stick
X
Duty Cycle
S
Gas Metal Arc
Welding (GMAW)
MIG / Gun Control
Self-Shielded Flux
Cored Arc Welding (SMAW)
Alternating
Current (AC)
Rated Welding
Current
V
Voltage
Increase
Negative
Line Connection
Gas Metal Arc
Welding (GMAW)
Suitable for Some
Hazardous
Locations
Gas Tungsten Arc
Welding (GTAW)
Torch
Lift Arc (GTAW)
TIG / Remote
Shielded Metal Arc
Welding (SMAW)
Hz
Hertz
Single Phase
Static Frequency
Converter-
Transformer-
Rectifier
Input Power Or Input Voltage
Wire Feed Spool
Gun / MIG Aluminum
Notes
OM-253 392 Page 12
.
A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Specifications For MIG (GMAW)
Input
Voltage
Rated Welding
Output
Amperage
Range
Maximum
Open-Circuit
Voltage DC
Amperes Input at Rated
Load Output, 50/60 Hz,
Single-Phase
IP
Rating
110 A @ 19.5 Volts DC,
20% Duty Cycle 22.4
30 − 140 90
75 A @ 17.75 Volts DC,
100% Duty Cycle*
14.6*
120 VAC
Wire Type
And Dia
Solid/Stainless
.023 - .035 in.
(0.6 - 0.8 mm)
Flux Cored
.030 - .035 in.
(0.8 - 0.9 mm)
Wire Feed Speed Range
70 − 425 IPM (1.75 − 10.8 m/min)
150 A @ 21.5 Volts DC,
20% Duty Cycle 17.5
IP23**
230 VAC
120 A @ 20 Volts DC,
100% Duty Cycle*
30 − 200 90
13.1*
Wire Type
And Dia
Solid/Stainless
.023 − .035 in.
(0.6 − 0.9 mm)
Flux Cored
.030 − .045 in.
(0.8 − 1.2 mm)
Wire Feed Speed Range
70 − 425 IPM (1.75 − 10.8 m/min)
* CSA Rating
**This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered.
4-2. Specifications For TIG (GTAW)
Input
Voltage
Rated Welding
Output
Amperage
Range
Maximum
Open-Circuit
Voltage DC
Amperes Input at Rated
Load Output, 50/60 Hz,
Single-Phase
IP
Rating
150 A @ 16 Volts DC,
30% Duty Cycle
120 VAC
70 A @ 13 Volts DC,
100% Duty Cycle*
150 A @ 16 Volts DC,
30% Duty Cycle
230 VAC
100 A @ 14 Volts DC,
100% Duty Cycle*
* CSA Rating
5 − 150
5 − 150
90
90
27.0
10.5*
13.8
15.9*
IP23**
**This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered.
4-3. Specifications For Stick (SMAW)
Input
Voltage
Rated Welding
Output
Amperage
Range
Maximum
Open-Circuit
Voltage DC
Amperes Input at Rated
Load Output, 50/60 Hz,
Single-Phase
IP
Rating
100 A @ 24 Volts DC,
35% Duty Cycle 23.8
120 VAC
70 A @ 22.8 Volts DC,
100% Duty Cycle*
20 − 100 90
16.5*
150 A @ 26 Volts DC,
30% Duty Cycle 20.8
IP23**
230 VAC
100 A @ 24 Volts DC,
100% Duty Cycle*
20 − 150 90
12.7*
* CSA Rating
**This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered.
OM-253 392 Page 13
.
A complete Parts List is available at www.MillerWelds.com
4-4. Dimensions And Weight
9-3/4 in.
(248 mm)
Weight
29 lb (13.2 kg)
14-1/2 in.
(368 mm)
17 in.
(432 mm)
Notes
253 921-B
Work like a Pro!
Pros weld and cut safely. Read the safety rules at the beginning of this manual.
OM-253 392 Page 14
.
A complete Parts List is available at www.MillerWelds.com
4-5. Duty Cycle And Overheating For MIG
80
60
40
20
0
10
200
180
160
140
120
100
120VAC
230VAC
20
20% Duty Cycle At 110A
% Duty Cycle
120V Input
50 100
100% Duty Cycle At 75A
Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
If unit overheats, output stops. Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle before starting to weld again.
NOTICE − Exceeding duty cycle can damage unit and void warranty.
2 Minutes Welding 8 Minutes Resting
230V Input
20% Duty Cycle At 150A
Continuous
Welding
100% Duty Cycle At 120A
2 Minutes Welding
Overheating
8 Minutes Resting
0
Minutes
15
Continuous
Welding
A or V
OR
Reduce Duty Cycle duty1 4/95 − Ref. Duty Cycle Charts
OM-253 392 Page 15
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4-6. Duty Cycle And Overheating For TIG
200
180
160
140
230V & 120V 20A
120
100
80
60
40
20
0
10
120V 15A
50 100
Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
If unit overheats, output stops. Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle before starting to weld again.
NOTICE − Exceeding duty cycle can damage unit and void warranty.
30
% Duty Cycle
120V Input
30% Duty Cycle At 150A
100% Duty Cycle At 75A
3 Minutes Welding 7 Minutes Resting
230V Input
30% Duty Cycle At 150A
Continuous
Welding
100% Duty Cycle At 100A
3 Minutes Welding
Overheating
7 Minutes Resting
0
Minutes
15
Continuous
Welding
A or V
OR
Reduce Duty Cycle duty1 4/95 − Ref. Duty Cycle Charts
OM-253 392 Page 16
.
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4-7. Duty Cycle And Overheating For Stick
80
60
40
20
0
10
200
180
160
140
120
100
230V
120V 20A
120V 15A
30
% Duty Cycle
50 100
Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
If unit overheats, output stops. Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle before starting to weld again.
NOTICE − Exceeding duty cycle can damage unit and void warranty.
120V Input
35% Duty Cycle At 100A
100% Duty Cycle At 70A
3-1/2 Minutes Welding 6-1/2 Minutes Resting
230V Input
30% Duty Cycle At 150A
Continuous
Welding
100% Duty Cycle At 100A
3 Minutes Welding
Overheating
7 Minutes Resting
0
Minutes
15
Continuous
Welding
A or V
OR
Reduce Duty Cycle duty1 4/95 − Ref. Duty Cycle Charts
OM-253 392 Page 17
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SECTION 5 − INSTALLATION
5-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the side. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
5-2. Selecting A Location
Tipping
!
Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC
Section 20.
1 Line Disconnect Device
Locate unit near correct input power supply.
Location
1
!
Do not move or operate unit where it could tip.
18 in.
(460 mm)
18 in.
(460 mm) loc_2 3/96 - 253 921-B
OM-253 392 Page 18
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5-3. Stick Welding Connections
!
Turn off unit and disconnect input power before making connections.
1 Positive Weld Output
Receptacle
2 Negative Weld Output
Receptacle
3 Stick Electrode Holder And
Cable
4 Work Clamp And Cable
Connect stick electrode holder cable to the positive weld output receptacle, and connect work clamp to negative weld output receptacle.
Ensure all connections are tight.
1
2
3
4
Ref. 254 251-B
OM-253 392 Page 19
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5-4. TIG Welding Connections DCEN (Direct Current Electrode Negative)
4
1
2
3
!
Turn off unit and disconnect input power before making connections.
1 Positive Weld Output
Receptacle
2 Negative Weld Output
Receptacle
3 TIG Torch And Cable
4 Work Clamp And Cable
Connect TIG torch cable to the negative weld output receptacle and connect work clamp to positive weld output receptacle.
Ensure all connections are tight.
5 Foot Control
6 Finger Tip Control
7 Remote Control Cable
8 Six Pin Remote Control
Receptacle
Route control cable through MIG gun hole.
Connect foot control or finger tip control to six pin remote control receptacle.
9 TIG Shielding Gas
Connection
Use Argon gas for TIG welding (see
5
8
6
7
OM-253 392 Page 20
9
Ref. 254 251-B / Ref. 254 249-B / Ref. 254 247-B
.
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5-5. Process/Polarity Table
Process
FCAW − Self-shielding wire − no shielding gas
Polarity
GMAW − Solid wire with shielding gas DCEP − Reverse polarity
DCEN − Straight Polarity
Cable Connections
Wire Drive Assembly Cable
Connect to positive (+) output receptacle
Connect to negative (−) output receptacle
Work Cable
Connect to negative (−) output receptacle
Connect to positive (+) output receptacle
5-6. Wire Welding Connections
1
2
4
3
MIG − DCEP
(Direct Current Electrode Positive)
1
2
4
3
Flux-Cored − DCEN
(Direct Current Electrode Negative)
7
6
8
5
!
Turn off unit and disconnect input power before making connections.
1 Positive Weld Output Receptacle
2 Negative Weld Output Receptacle
3 Wire Drive Assembly Cable
4 Work Clamp And Cable
Ensure all connections are tight.
5 Gun End
Connect gun end to drive assembly (see
6 Trigger Control Cable
7 Four Pin Trigger Control Cable
Receptacle
Route trigger control cable through MIG gun hole.
Ref. 254 252-B / Ref. 254 249-A / Ref. 254 247-B
Connect plug on end of cable to four pin receptacle inside unit.
8 MIG Shielding Gas Connection
Use 75/25 mix or CO
2
shielding gas for solid wire. Use Argon shielding gas for aluminum wire with spool gun (see Section
OM-253 392 Page 21
.
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5-7. Wire Gun Connection Inside Unit
6
5
1 Gun Securing Knob
2 Gun Block
3 Gun Outlet Wire Guide
4 Gun End
1
2
3 4
Loosen knob. Insert end of gun through opening in front panel until gun end
bottoms against gun block. Tighten knob.
5 Trigger Control Cable
Ref. 254 249-A
6 Four Pin Trigger Control Cable
Receptacle
Route trigger control cable through MIG gun hole.
Connect plug on end of cable to four pin receptacle inside unit.
.
Be sure that gun end is tight against drive assembly.
4 4
Correct Incorrect
Ref. 801 987
OM-253 392 Page 22
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5-8. Connecting Shielding Gas Supply
2
3
1
2
1
3
Mixed Gas
10
9
8
CO
2
Gas
4
5 5
Argon Gas
4
8
1
3
2
Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve.
1 Cap
2 Cylinder Valve
Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve.
Close valve.
3 Cylinder
4 Regulator/Flowmeter
Install so face is vertical.
5 Regulator/Flowmeter Gas
Hose Connection
6 Welding Power Source CO
And Mixed Gas Hose
Connection
2
7 Welding Power Source Argon
Gas Hose Connection
Connect gas hose between regulator/flowmeter gas hose connection, and the appropriate fitting for the gas type on rear of welding power source.
8 Flow Adjust
Typical flow rate for CO
2
shielding gas and MIG (GMAW) welding is 15 to 30 cfh (cubic feet per hour) and mixed gas is 25 to 45 cfh.
Typical flow rate for Argon shielding gas and TIG (GTAW) welding is 15 to 25 cfh and aluminum MIG
(GMAW) welding is 35 to 45 cfh.
Check wire manufacturer’s recommended flow rate.
9 CO2 Adapter (Customer
Supplied)
10 O-Ring (Customer Supplied)
Install adapter with O-ring between regulator/flowmeter and CO
2 cylinder.
6
7
MIG TIG
Tools Needed:
1-1/8, 5/8 in.
Ref. 804 654-A / 254 247-B
OM-253 392 Page 23
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5-9. Electrical Service Guide
Elec Serv 2011−08
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
.
Actual input voltage should not exceed 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not be available.
50/60 Hz 230
Single Phase
230
17.7
50/60 Hz 120
Volts AC
Input Voltage (V)
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2
Normal Operating Fuses 3
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
A 15 or 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required.
See Section
Min Grounding Conductor Size In AWG 4
20
25
14
65
(20)
14
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
5-10. Extension Cord Data
Input Voltage
120 V
230 V
Input Power
Phase
1
1
Hertz
50/60
50/60
Conductor Size
14 AWG
14 AWG
Max. Cord Length
24 ft (7 m)
65 ft (20 m)
OM-253 392 Page 24
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5-11. Multi−Voltage Plug (MVP) Connection
2
Selecting Plug
1
3
4
5
6
!
Do not cut off power cord connector and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product warranty.
7
Connecting Plug To Power Cord
Selecting Plug
1 Power Cord Connector From
Welding Power Source
Select plug for power supply receptacle available at site. Not all plugs shown are provided as standard with unit.
2 Plug − NEMA Type 5−15P
3 Receptacle − NEMA Type 5−15R
(Customer Supplied)
4 Plug − NEMA Type 5−20P (Optional)
5 Receptacle − NEMA Type 5−20R
(Customer Supplied)
6 Plug − NEMA Type 6−50P
7 Receptacle − NEMA Type 6−50R
(Customer Supplied)
!
Follow electrical service guide for
230 VAC in Section 5-9. Do not use
plug rating to size branch circuit protection.
MVP Plug1 2010−10 / Ref. 803 812-C
Connecting Plug To Power Cord
Align arrow on plug with arrow on power cord connector. Push together.
Tighten threaded collar. As threaded collar is tightened, push plug onto adapter until collar is completely tight.
Connect plug to receptacle.
OM-253 392 Page 25
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5-12. Connecting 115 Volt Input Power
1 2
!
Installation must meet all
National and Local Codes − have only qualified persons make this installation.
!
Special installation may be required where gasoline or volatile liquids are present − see NEC
Article 511 or CEC Section 20.
.
The Auto-Line circuitry in this unit automatically links the power source to the primary voltage being applied, either 115 or 230 VAC.
See rating label on unit and check input voltage available at site.
For 115 volts AC input power, a 15 or 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required.
1 Multi-Voltage Plug And Power Cord
Connector (NEMA Type 5−15P Plug
Shown)
For multi−voltage plug connections, see
1 Plug From Unit
2 Receptacle − NEMA Type 5−15R
(Customer Supplied)
Input6 2011−03 253 921-B / Ref. 805 474-A
OM-253 392 Page 26
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5-13. Connecting 1-Phase Input Power For 230 VAC
1
8
L2
5
2
230 VAC, 1
L1
3
4
L1
L2
6
7
1
=GND/PE Earth Ground
!
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.
See rating label on unit and check input voltage available at site.
1 Black And White Input Conductor
(L1 And L2)
2 Green Or Green/Yellow Grounding
Conductor
3 Input Power Cord.
4 Disconnect Device (switch shown in the OFF position)
5 Disconnect Device Grounding
Terminal
6 Disconnect Device Line Terminals
Connect green or green/yellow grounding conductor to disconnect device grounding terminal first.
Connect input conductors L1 and L2 to disconnect device line terminals.
7 Over-Current Protection
Select type and size of over-current
protection using Section 5-9 (fused
disconnect switch shown).
8 Receptacle (NEMA 6-50R)
Customer Supplied
Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.
Tools Needed:
input4 2011-03 − 803 766-B / Ref. 802 443-A / 253 921-B
OM-253 392 Page 27
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5-14. Installing Wire Spool And Adjusting Hub Tension
1 Wire Spool
2 Retaining Nut [For 8 in. (203 mm) Spool Only]
1
2
Installing 4 in. (102 mm) Wire Spool
When a slight force is needed to turn spool, tension is set.
Installing 8 in. (203 mm) Wire Spool
Adapter used with 8 in.
(203 mm) spool only.
Tools Needed:
When a slight force is needed to turn spool, tension is set.
Retaining ring used with 8 in.
(203 mm) spool only.
1/2 in.
Align locking hole in spool with locking pin on spool hub.
Ref. 254 253-A / 803 012 / 803 013 -B / Ref. 802 444-C
OM-253 392 Page 28
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5-15. Threading Welding Wire
4
1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
6 Outlet Wire Guide
7 Gun Conduit Cable
Lay gun cable out straight.
7
Tools Needed:
1 2 3 5 6
.
Hold wire tightly to keep it from unraveling.
Open pressure assembly.
Tighten
3
4
1
2
Pull and hold wire; cut off end.
Push wire thru guides into gun; continue to hold wire.
.
Use pressure indicator scale to set a desired drive roll pressure. Begin with a setting of 2.
If necessary, make additional adjustments after trying this initial setting.
Pressure
Indicator
Scale
Close and tighten pressure assembly, and let go of wire.
Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle
Remove gun nozzle and contact tip.
Tighten
1
2
3
4 WOOD
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Turn On.
Cut off wire. Close and latch door.
Ref. 254 253-A / Ref. 804 913-A
OM-253 392 Page 29
6-1. Controls
.
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SECTION 6 − OPERATION
2
1 Process Select Knob
Turn knob to select the desired welding process.
2 Auto-Set Button
Press button to turn Auto-Set On or
Off.
3 Wire/Rod/Tungsten Buttons
Press the Plus (+) or Minus (−) button to select the size of wire, rod, or tungsten for the selected process.
4 Material Thickness Buttons
Press the Plus (+) or Minus (−) button to select material thickness for the selected process.
5 Display
6 Adjustment Knob
1
4
3
5
6
6
Ref. 249 632-E
OM-253 392 Page 30
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6-2. Weld Parameter Chart
Ref. 252 671-C
OM-253 392 Page 31
1
3
.
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6-3. Entering Setup Menu
1 Wire/Rod/Tungsten Minus (−)
Button
2 Material Thickness Plus (+)
Button
3 Display
When unit is turned off, press and hold Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus
(+) button simultaneously.
Turn unit power on.
When Display shows MULTIMATIC
200 setup screen, release the two buttons simultaneously.
The contrast adjustment screen should be displayed.
2
Ref. 249 632-E
OM-253 392 Page 32
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6-4. Adjusting Display Contrast (Menu 1 Of 9)
1 Adjustment Knob
2 Material Thickness Plus (+)
Button
Follow instructions in Section 6-3 to
enter the setup menu.
The Display Contrast should now appear on the display.
To adjust display contrast, turn either Adjustment knob.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
2
1
1
Ref. 249 632-E
6-5. Calibrating Drive Motor (Menu 2 Of 9)
.
The unit’s internal drive motor is calibrated at the factory. No calibration is needed unless drive motor or user interface board is changed. Contact nearest factory authorized Service Agent or Miller Electric Mfg. Co. Service department.
OM-253 392 Page 33
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6-6. Calibrating Spoolmate 100 (Menu 3 Of 9)
2
3
1
1 Material Thickness Plus (+)
Button
2 Left Adjustment Knob
3 Right Adjustment Knob
.
Spoolmate 100 drive motors are unique to this welding power source. Motor calibration is necessary any time a different Spoolmate 100 is connected to the Multimatic 200.
Connect Spoolmate 100 to unit. Cut wire flush at nozzle.
Follow instructions in Section 6-3 to
enter the setup menu.
Press Material Thickness Plus (+) button twice after entering setup to enter the Spoolmate Calibration menu.
To perform a Spoolmate calibration
24 in. runout test at 100 ipm, turn left
Adjustment knob and verify that a
(n) check mark appears next to
100 IPM. Be sure that wire is cut flush at nozzle, then trigger the
Spoolmate 100.
Spoolmate will feed approximately
24 in. of wire through gun.
Cut wire flush at nozzle and measure run-out.
If wire is not 24 inches long, use left
Adjustment knob to increase or decrease the length of the run-out and repeat the test.
To perform a Spoolmate calibration
24 in. runout test at 300 ipm, turn right Adjustment knob and verify that a (n) check mark appears next to 300 IPM. Be sure tthat wire is cut flush at nozzle, then trigger the
Spoolmate 100.
Spoolmate will feed approximately
24 in. of wire through gun.
Cut wire flush at nozzle and measure run-out.
If wire is not 24 inches long, use right Adjustment knob to increase or decrease the length of the run-out and repeat the test.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
Tools Needed:
Ref. 249 632-E
OM-253 392 Page 34
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6-7. Viewing Burn-In Information (Menu 4 Of 9)
.
Burn-In information is for factory and service use only.
Follow instructions in Section 6-3 to enter the setup menu.
Press Material Thickness Plus (+) button three times after entering setup to enter the Burn-In information screen.
Burn-In information displays electrical information unique to the unit.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
6-8. Viewing Software Information (Menu 5 Of 9)
.
Software information is for factory and service use only.
Follow instructions in Section 6-3 to enter the setup menu.
Press Material Thickness Plus (+) button four times after entering setup to enter the Software information screen.
Software information displays software information unique to the unit.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
6-9. Viewing Primary Power Information (Menu 6 Of 9)
.
Primary Power information is for factory and service use only.
Follow instructions in Section 6-3 to enter the setup menu.
Press Material Thickness Plus (+) button five times after entering setup to enter the Primary Power Logs screen.
Primary Power Logs screen displays unit power on time.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
Notes
Work like a Pro!
Pros weld and cut safely. Read the safety rules at the beginning of this manual.
OM-253 392 Page 35
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6-10. Viewing Process Logs (Menu 7 Of 9)
1 Material Thickness Plus (+)
Button
2 Process Select Knob
Follow instructions in Section 6-3 to
enter the setup menu.
Press Material Thickness Plus (+) button six times after entering setup to enter the Process Logs screen.
Process Logs screen displays manual minutes, Auto-Set minutes, weld cycles, and Auto-Set cycles for the selected process.
To view other processes, use the
Process Select knob to select the desired weld process.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
2
1
Ref. 249 632-E
OM-253 392 Page 36
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6-11. Viewing Error Logs (Menu 8 Of 9)
1 Material Thickness Plus (+)
Button
Follow instructions in Section 6-3 to
enter the setup menu.
Press Material Thickness Plus (+) button seven times after entering setup to enter the Process Logs screen.
Error Logs screen displays unit over-temperature errors, shorted output errors, shorted trigger errors, input voltage errors, and input current errors.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.
1
Ref. 249 632-E
OM-253 392 Page 37
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6-12. Performing A Factory Reset (Menu 9 Of 9)
2
1 Material Thickness Plus (+)
Button
2 Auto-Set Button
.
A Factory Reset will reset the primary log data, process log data, and error log data. Contrast settings, motor calibration settings, Spoolmate Calibration settings, Burn-In information, and Software information will all be retained.
Follow instructions in Section 6-3 to
enter the setup menu.
Press Material Thickness Plus (+) button eight times after entering setup to enter the Factory Reset screen.
To perform a Factory Reset, press the Auto-Set button. To exit this screen without performing a factory reset, press the Material Thickness
Plus (+) button.
1
Ref. 249 632-E
OM-253 392 Page 38
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SECTION 7 − MAINTENANCE &TROUBLESHOOTING
7-1. Routine Maintenance
!
Disconnect power before maintaining.
.
Maintain more often during severe conditions.
n = Check Z = Change ~ = Clean
* To be done by Factory Authorized Service Agent l = Replace Reference
Every
3
Months l Damaged Or Unreadable
Labels
l Repair Or Replace
Cracked Weld Cable
Every
6
Months
OR
~ Inside Unit ~ Clean Drive Rolls
7-2. Overload Protection
1 Supplementary Protector CB1
CB1 protects unit from overload. If
CB1 opens, unit shuts down.
Reset supplementary protector.
1
253 923-B
OM-253 392 Page 39
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7-3. Changing Drive Roll Or Wire Inlet Guide
.030/.035 Groove
1
2
.024 Groove
3
1 Inlet Wire Guide
Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place.
2 Drive Roll
The drive roll consists of two different sized grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to
3 Retaining Pin
To secure drive roll, locate open slot and push drive roll completely over retaining pin, then rotate drive roll
1/4 turn to closed slot.
Stamped .024
Stamped .030/.035
802 984-A
7-4. Error Messages
Message
NETWORK 1 ERROR
NETWORK 2 ERROR
CABLE ERROR
OVERTEMP
SHORTED OUTPUT ERROR
ROD STUCK ERROR
SHORTED 4-PIN TRIGGER
ERROR
OM-253 392 Page 40
Error Remedy
The two microcontrollers on the control board are no longer communicating.
Cycle the power to clear this error. If this error persists after a power cycle, contact Miller Electric
Mfg. Co. service department.
The microcontroller on the user interface board is no longer communicating with the microcontroller on the control board.
Cycle the power to clear this error. If this error persists after a power cycle, contact Miller Electric
Mfg. Co. service department.
The microcontroller on the user interface board is no longer communicating with the microcontroller on the control board.
Connect the wire drive assembly cable to either the positive or negative stud, or select a different process.
A process that requires a welding gun to not be attached to the internal motor is selected, but the wire drive assembly cable is attached to either the positive or negative stud of the power source.
The internal temperature of the unit has exceeded the maximum limit.
Remove the wire drive assembly cable to either the positive or negative stud, or select a different process.
Wait for the unit to cool down. If the fan is not running, contact Miller Electric Mfg. Co. service department.
Once the trigger has been released, the error will clear.
The unit had determined that the welding gun has become shorted to the workpiece and turned off the output.
The unit had determined that the stick welding rod has become stuck in the welding puddle and turned off the output.
The 4-pin trigger has been held down on power up, or the trigger has been held too long without initiating an arc.
Remove the stick welding rod from the workpiece and the output will turn back on after about 1 second.
Release the 4-pin trigger.
.
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Message
SHORTED 6-PIN REMOTE
ERROR
Error
The 6-pin remote has been held down on power up, or the remote has been held too long without initiating an arc.
Too much current has passed through the inverter bridge circuit of the unit.
Remedy
Release the 6-pin remote.
BRIDGE CURRENT ERROR
PRIMARY THERMISTOR
ERROR
SECONDARY THERMISTOR
ERROR
PRIMARY VOLTAGE ERROR
PRIMARY CURRENT ERROR
PRIMARY BOOST NOT READY
The primary circuit thermistor is reading too high or too low for a valid temperature.
The secondary circuit thermistor is reading too high or too low for a valid temperature.
The primary voltage has exceeded the maximum allowable limit.
Too much current has passed through the primary circuit of the unit.
The primary boost has not successfully been established.
Cycle the power to clear this error. If this error persists after a power cycle, contact Miller Electric
Mfg. Co. service department.
Contact Miller Electric Mfg. Co. service department.
Contact Miller Electric Mfg. Co. service department.
Reduce the primary voltage to an acceptable level.
Cycle the power to clear this error. If this error persists after a power cycle, contact Miller Electric
Mfg. Co. service department.
Cycle the power to clear this error. If this error persists after a power cycle, contact Miller Electric
Mfg. Co. service department.
7-5. Troubleshooting
Trouble
No weld output; unit completely inoperative.
No weld output; unit is on.
Erratic or improper welding arc or output.
Fan not operating.
Stick welding problems: Hard starts; poor welding characteristics; unusual spattering.
TIG welding problems: Wandering arc; hard starts; poor welding characteristics; spattering problems.
TIG welding problems: Tungsten electrode oxidizing and not remaining bright after welding.
Remedy
Place line disconnect switch in On position.
Check and replace line fuse(s), if necessary, or reset supplementary protector.
Be sure power cord is plugged in and that receptacle is receiving input power.
Check and secure loose weld cable(s) into receptacle(s).
Check and correct poor connection of work clamp to workpiece.
Unit overheated causing thermal shutdown. Allow unit to cool with fan On (see Section 4-5,4-6 and
Reduce duty cycle or amperage.
Check and correct blocked/poor airflow to unit (see Section 5-2).
Turn Power Off and back On again. If light continues to flash, check with Factory Authorized Service
Agent.
Line voltage too high or too low. Line voltage must be within
10%.
Remote trigger left on. Turn off remote trigger, wait five seconds, and restart operation.
Use proper size and type of weld cable (see your Distributor).
Clean and tighten weld connections.
Verify electrode polarity; check and correct poor connections to workpiece.
Unit not warmed up enough to require fan cooling.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor and control circuitry.
Use proper type and size of electrode.
Verify electrode polarity; check and correct poor connections.
Make sure a remote control is not connected.
Use proper type and size of tungsten.
Use properly prepared tungsten.
Verify electrode polarity.
Shield weld zone from drafts.
Check for correct type shielding gas.
Check and tighten gas fittings.
Verify electrode polarity.
OM-253 392 Page 41
SECTION 8 − ELECTRICAL DIAGRAM
OM-253 392 Page 42
Figure 8-1. Circuit Diagram
251 419-C
OM-253 392 Page 43
SECTION 9 − MIG WELDING (GMAW) GUIDELINES
9-1. Typical MIG Process Connections
mig1 2009−12
!
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.
Regulator/
Flowmeter
Wire Feeder/
Power Source
Shielding Gas
Gas
Gun
Work Clamp
Workpiece
Ref. 801 909-A
OM-253 392 Page 44
9-2.
Typical MIG Process Control Settings
.
These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications.
Material thickness determines weld parameters.
1/8 or 0.125 in.
Convert Material
Thickness to
Amperage (A)
(0.001 in. = 1 ampere)
0.125 in. = 125 A
.035 in
Wire Size
0.023 in.
0.030 in.
0.035 in.
Amperage Range
30 − 90 A
40 − 145 A
50 − 180 A
Select Wire Size
Wire
Size
0.023 in.
0.030 in.
0.035 in.
Recommendation
3.5 in. per ampere
2 in. per ampere
1.6 in. per ampere
Wire Speed
(Approx.)
3.5 x 125 A = 437 ipm
2 x 125 A = 250 ipm
1.6 x 125 A = 200 ipm
Select Wire Speed
(Amperage)
125 A based on 1/8 in.
material thickness ipm = inches per minute
Low voltage: wire stubs into work
High voltage: arc is unstable (spatter)
Set voltage midway between high/low voltage
Voltage controls height and width of weld bead.
Select Voltage
Wire speed (amperage) controls weld penetration (wire speed = burn-off rate)
OM-253 392 Page 45
9-3.
Holding And Positioning Welding Gun
.
Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam.
2
3
1 Hold Gun and Control Gun
Trigger
2 Workpiece
3 Work Clamp
4 Electrode Extension (Stickout)
1/4 to 1/2 in. (6 To 13 mm)
5 Cradle Gun and Rest Hand on
Workpiece
5
1
4
0 -15
90 90
End View of Work Angle Side View of Gun Angle
GROOVE WELDS
45 0 -15
45
End View of Work Angle Side View of Gun Angle
FILLET WELDS
S-0421-A
OM-253 392 Page 46
9-4.
Conditions That Affect Weld Bead Shape
.
Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed
(weld current), and voltage.
10
Push
10
Perpendicular Drag
GUN ANGLES AND WELD BEAD PROFILES
Short Normal
ELECTRODE EXTENSIONS (STICKOUT)
Long
Short Normal Long
FILLET WELD ELECTODE EXTENSIONS (STICKOUT)
Slow Normal
GUN TRAVEL SPEED
Fast
S-0634
OM-253 392 Page 47
9-5.
Gun Movement During Welding
.
Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better.
1 2
1 Stringer Bead − Steady
Movement Along Seam
2 Weave Bead − Side To Side
Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide area in one pass of the electrode.
3
9-6.
Poor Weld Bead Characteristics
1
S-0054-A
1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration
2 3 4
5
9-7.
Good Weld Bead Characteristics
1
S-0053-A
1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals being welded.
4 No Overlap
5 Good Penetration into Base
Metal
2 3 4
5
S-0052-B
OM-253 392 Page 48
9-8.
Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.
Possible Causes
Wire feed speed too high.
Voltage too high.
Electrode extension (stickout) too long.
Workpiece dirty.
Insufficient shielding gas at welding arc.
Dirty welding wire.
S-0636
Corrective Actions
Select lower wire feed speed.
Select lower voltage range.
Use shorter electrode extension (stickout).
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
Check polarity required by welding wire, and change to correct polarity at welding power source.
Incorrect polarity.
9-9.
Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets in weld metal.
S-0635
Possible Causes
Insufficient shielding gas at welding arc.
Corrective Actions
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.
Wrong gas.
Dirty welding wire.
Hold gun near bead at end of weld until molten metal solidifies.
Use welding grade shielding gas; change to different gas.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
9-10. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
S-0639
OM-253 392 Page 49
9-11. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow fusion between weld metal and base metal.
Lack of Penetration Good Penetration
Possible Causes
Improper joint preparation.
Improper weld technique.
Insufficient heat input.
Incorrect polarity.
S-0638
Corrective Actions
Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
Check polarity required by welding wire, and change to correct polarity at welding power source.
9-12. Troubleshooting − Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead.
Possible Causes
Workpiece dirty.
Insufficient heat input.
Improper welding technique.
S-0637
Corrective Actions
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Select higher voltage range and/or adjust wire feed speed.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
9-13. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.
S-0640
Possible Causes
Excessive heat input.
OM-253 392 Page 50
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
9-14. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
S-0641
Possible Causes Corrective Actions
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Unsteady hand.
Support hand on solid surface or use two hands.
9-15. Troubleshooting − Distortion
Possible Causes
Excessive heat input.
Distortion − contraction of weld metal during welding that forces base metal to move.
Base metal moves in the direction of the weld bead.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
S-0642
OM-253 392 Page 51
9-16. Common MIG Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
Gas
Spray Arc Steel
Application
Short Circuiting Steel
Short Circuiting
Stainless Steel
Aluminum
X Argon
Argon + 25% CO
2
80% or greater Argon + balance CO
2
or Oxygen
100% CO
2
Tri-Mix2
1 Limited short circuiting use
2 90% HE + 7-1/2% AR + 2-1/2% CO
2
X
X
X
X
1
X
9-17. Troubleshooting Guide For Semiautomatic Welding Equipment
Problem
Wire feed motor operates, but wire does not feed.
Probable Cause
Too little pressure on wire feed rolls.
Incorrect wire feed rolls.
Remedy
Increase pressure setting on wire feed rolls.
Wire spool brake pressure too high.
Restriction in the gun and/or assembly.
Check size stamped on wire feed rolls, replace to match wire size and type if necessary.
Decrease brake pressure on wire spool.
Check and replace cable, gun, and contact tip if damaged. Check size of contact tip and cable liner, replace if necessary.
Wire curling up in front of the wire feed rolls (bird nesting).
Too much pressure on wire feed rolls.
Incorrect cable liner or gun contact tip size.
Decrease pressure setting on wire feed rolls.
Check size of contact tip and check cable liner length and diameter, replace if necessary.
Gun end not inserted into drive housing properly.
Dirty or damaged (kinked) liner.
Wire feeds, but no gas flows. Gas cylinder empty.
Gas nozzle plugged.
Replace empty gas cylinder.
Clean or replace gas nozzle.
Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.
Restriction in gas line.
Loose or broken wires to gas solenoid.
Gas solenoid valve not operating.
Loosen gun securing bolt in drive housing and push gun end into housing just enough so it does not touch wire feed rolls.
Replace liner.
Check gas hose between flowmeter and wire feeder, and gas hose in gun and cable assembly.
Have Factory Authorized Service Agent repair wiring.
Have Factory Authorized Service Agent replace gas solenoid valve.
Incorrect primary voltage connected to welding power source.
Check primary voltage and relink welding power source for correct voltage.
OM-253 392 Page 52
Problem
Welding arc not stable.
Probable Cause
Wire slipping in drive rolls.
Remedy
Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary.
Wrong size gun liner or contact tip.
Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on welding power source.
Readjust welding parameters.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun.
Repair or replace gun as necessary.
OM-253 392 Page 53
SECTION 10 − STICK WELDING (SMAW) GUIDELINES
10-1. Stick Welding Procedure
Tools Needed:
2
4
5
Equipment Needed:
Constant Current
Welding Power Source
6
3
!
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.
.
Always wear appropriate personal protective clothing.
1 Workpiece
Make sure workpiece is clean before welding.
2 Work Clamp
3 Electrode
A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld
4 Insulated Electrode Holder
5 Electrode Holder Position
6 Arc Length
Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound.
7 Slag
Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass.
1 7 stick 2010−02 − 151 593
OM-253 392 Page 54
10-2. Electrode and Amperage Selection Chart
6010
&
6011
6013
7014
7018
7024
Ni-Cl
308L
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
3/16
3/32
1/8
5/32
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
10-3. Striking an Arc
6010
6011
6013
EP
EP
EP,EN
ALL
ALL
ALL
DEEP
DEEP
LOW
MIN. PREP, ROUGH
HIGH SPATTER
7014
7018
EP,EN
EP
ALL
ALL
MED
MED
GENERAL
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
NI-CL
308L
EP,EN
EP
EP
FLAT
HORIZ
FILLET
ALL
ALL
LOW
LOW
LOW
SMOOTH, EASY,
FASTER
CAST IRON
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
1
1
3
3
2
2
Ref. S-087 985-A
1 Electrode
2 Workpiece
3 Arc
Scratch Technique
Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.
Tapping Technique
Bring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.
S-0049 / S-0050
OM-253 392 Page 55
10-4. Positioning Electrode Holder
1 End View Of Work Angle
2 Side View Of Electrode Angle
1
90 90
10 -30
2
Groove Welds
1
45
45
Fillet Welds
10-5. Poor Weld Bead Characteristics
10 -30
2
S-0060
1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration
2 3
4
1
10-6. Good Weld Bead Characteristics
1
2 3 4
5
S-0053-A
5
1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals being welded.
4 No Overlap
5 Good Penetration into Base
Metal
S-0052-B
OM-253 392 Page 56
10-7. Conditions That Affect Weld Bead Shape
Electrode Angle
Angle Too Small
Correct Angle
10 - 30
Drag
Arc Length
Too Short Normal
Travel Speed
Slow Normal
10-8. Electrode Movement During Welding
Angle Too Large
Too Long
Spatter
Fast
.
Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal.
S-0061
1
3
2
.
Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better.
1 Stringer Bead − Steady
Movement Along Seam
2 Weave Bead − Side to Side
Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode.
S-0054-A
OM-253 392 Page 57
10-9. Groove (Butt) Joints
1
10-10. Lap Joint
2
10-11. Tee Joint
3
1
2
45
Or
Less
30
1/16 in.
(1.6 mm)
30
Or Less
1
2
3
2
4
30
Or Less
1
1 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 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.
Create 30 degree angle of bevel on materials in V-groove welding.
4 Double V-Groove Weld
Good for materials thicker than
3/16 in. (5 mm).
S-0062
1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.
3 Multi-Layer Fillet Weld
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
S-0063 / S-0064
3
1
1 Electrode
2 Fillet Weld
Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface.
For maximum strength weld both sides of upright section.
3 Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section
10-8. Remove slag before making
another weld pass.
S-0060 / S-0058-A / S-0061
OM-253 392 Page 58
10-12. Weld Test
3
1 Vise
2 Weld Joint
3 Hammer
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)
10-13. Troubleshooting
2
1
2
1
Porosity − small cavities or holes resulting from gas pockets in weld metal.
S-0057-B
Possible Causes
Arc length too long.
Damp electrode.
Workpiece dirty.
Corrective Actions
Reduce arc length.
Use dry electrode.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.
Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.
Possible Causes
Amperage too high for electrode.
Arc length too long or voltage too high.
Corrective Actions
Decrease amperage or select larger electrode.
Reduce arc length or voltage.
Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead.
Possible Causes
Insufficient heat input.
Improper welding technique.
Workpiece dirty.
Corrective Actions
Increase amperage. Select larger electrode and increase amperage.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.
OM-253 392 Page 59
Lack Of Penetration − shallow fusion between weld metal and base metal.
Lack of Penetration Good Penetration
Possible Causes
Improper joint preparation.
Improper weld technique.
Insufficient heat input.
Corrective Actions
Material too thick. Joint preparation and design must provide access to bottom of groove.
Keep arc on leading edge of weld puddle.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
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.
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. Practice technique.
Distortion − contraction of weld metal during welding that forces base metal to move.
Possible Causes
Excessive heat input.
Base metal moves in the direction of the weld bead.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-253 392 Page 60
SECTION 11 − SELECTING AND PREPARING A
TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2011-06
Whenever possible and practical, use DC weld output instead of AC weld output.
11-1. Selecting Tungsten Electrode ( Wear Clean Gloves To Prevent Contamination Of Tungsten )
.
Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference the product packaging to identify the tungsten you are using.
Electrode Diameter
Amperage Range - Gas Type - Polarity
(DCEN) − Argon
Direct Current Electrode Negative
(For Use With Mild Or Stainless Steel)
AC − Argon
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (1 mm)
.020 in. (1 mm)
.040 in. (1 mm)
1/16 in. (1.6 mm)
3/32 in. (2.4 mm)
1/8 in. (3.2 mm)
5/32 in. (4.0 mm)
3/16 in (4.8 mm)
1/4 in. (6.4 mm)
Up to 25
15-40
25-85
50-160
130-250
250-400
400-500
500-750
750-1000
Up to 20
15-35
20-80
50-150
135-235
225-360
300-450
400-500
600-800
Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines
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 tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
Radial Grinding
Causes Wandering Arc
Wrong Tungsten
Preparation
2
2-1/2 Times
Electrode Diameter
3
1
4
Ideal Tungsten Preparation − Stable Arc
1 Grinding Wheel
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 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Flat
Diameter of this flat determines amperage capacity.
4 Straight Ground
Grind lengthwise, not radial.
OM-253 392 Page 61
SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW)
12-1. Positioning The Torch
10−25
4
1
2
10−15
90
5
6
3
5
6
1/16 in.
3/16 in.
Bottom View Of Gas Cup
4
!
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. Keep flammables away.
1 Workpiece
Make sure workpiece is clean before welding.
2 Work Clamp
Place as close to the weld as possible.
3 Torch
4 Filler Rod (If Applicable)
5 Gas Cup
6 Tungsten Electrode
Select and prepare tungsten according
Guidelines:
The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage. (For example, if tungsten is 1/16 in. diameter, gas cup should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the tungsten extends out gas cup of torch.
The tungsten extension should be no greater than the inside diameter of the gas cup.
Arc length is the distance from the tungsten to the workpiece.
Ref. ST-161 892
OM-253 392 Page 62
12-2. Torch Movement During Welding
Tungsten Without Filler Rod
Welding direction
Form pool
Tungsten With Filler Rod
Welding direction
Form pool
Tilt torch
Tilt torch
75
75
15
Move torch to front of pool. Repeat process.
Add filler metal
Remove rod Move torch to front of pool. Repeat process.
12-3. Positioning Torch Tungsten For Various Weld Joints
Butt Weld And Stringer Bead
“T” Joint
ST-162 002-B
20
90
70
75
20
Lap Joint
10
15
Corner Joint
20-40
90
75
75
15
30
15
ST-162 003 / S-0792
OM-253 392 Page 63
SECTION 13 − PARTS LIST
13-1. Recommended Spare Parts
Item
No.
Part
No.
Description Quantity
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
301059 . .
Q−150 MIG gun (Includes)
43015
QJL−2330
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
4323R
DS−1
T−030
NS−1200B
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liner, 2/300A .023−.030 15 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
1
1
Liner, Jump Steel .023−030 1
Insulator, Nozzle (small)
Diffuser, Centerfire (small nozzle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip, Centerfire .030
Nozzle, Centerfire Small Brass 1/2 in. Flush
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
13-2. Drive Rolls
PART NO.
220 179
202 926
WIRE DIAMETER INCHES (mm)
.024 (.6) and .030/.035 (.8 and .9) (Standard)
.030/.035 (.8 and .9) and .045 (1.2 VK Groove)
13-3. Options
PART NO.
43110
QJL−3545
T−023
T−035
T−045
NS−5818C
NS−5800B
NS−5818B
NS−1218C
NS−1218B
DESCRIPTION
Liner, 2/300A
Liner, Jump Steel
Tip, Centerfire
Tip, Centerfire
Tip, Centerfire
Nozzle, Centerfire Small Copper
Nozzle, Centerfire Small Brass
Nozzle, Centerfire Small Brass
Nozzle, Centerfire Small Copper
Nozzle, Centerfire Small Brass
REMARKS
.035−.045 in. wire size, 10 ft length
.035−.045 in. wire size
.023 in.
.035 in.
.045 in.
5/8 in. Recess 1/8 in.
5/8 in. Flush
5/8 in. Recess 1/8 in.
1/2 in. Recess 1/8 in.
1/2 in. Recess 1/8 in.
A complete Parts List is available on-line at www.MillerWelds.com
OM-253 392 Page 64
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)
18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)
1/8 in. (.125 in.)
3/16 in. (.188 in.)
1/4 in. (.25 in.)
5/16 in. (.313 in.)
3/8 in. (.375 in.)
1/2 in. (.5 in.)
Notes
Warranty Questions?
Call
1-800-4-A-MILLER for your local
Miller distributor.
Your distributor also gives you ...
Service
You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Support
Need fast answers to the tough welding questions?
Contact your distributor.
The expertise of the distributor and Miller is there to help you, every step of the way.
Effective January 1, 2012
(Equipment with a serial number preface of MC or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.
6. 90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
* M-Guns
* MIG Guns and Subarc (SAW) Guns
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Roughneck Guns
* Spoolmate Spoolguns
Miller’s True Blue Limited Warranty shall not apply to:
Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an
International distributor.
1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.)
2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
2. 3 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
3. 2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
5. 6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B.,
Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS
EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
miller_warr 2012-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
City
State
Serial/Style Number
(Date which equipment was delivered to original customer.)
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Contact the Delivering Carrier to:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller
File a claim for loss or damage during shipment.
For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
2012 Miller Electric Mfg. Co. 2012−01
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit www.MillerWelds.com
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