CE

Miller

The Power

ofBlue.

OM107 439F

April 1997

Eff.

w/Se rial Number KH374223

Processes

~

~

Gas Tungsten Arc

(TIG) Welding

Shielded Metal Arc

(Stick) Welding

Description

Arc Welding Power Source lull

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Visit our website at www.millerweids.com

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! MANUAL

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Thank you and

congratulations

on

choosing

Miller.

Now you can

get

the

job

done and

get

it done

right.

We know you dont have time to do it any other way.

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Thats

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why

when Niels Miller first started

building

arc welders in

long-lasting

value and

superior

customers had to be more than the best be tradition.

1929,

he made sure his couldnt afford the best you could

buy.

products

offered

quality.

Like you, his

anything

less. Miller

products they

could be.

They

had to

Today,

the

people

that build and sell Miller

producl:s

continue the

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Theyre just

as committed to

providing equipment

and service r4~~j~k~

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high

standards of

quality

and value established in 1929.

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This Owners Manual is

designed

to

help

you

get

the most out of your

~

Miller

products.

Please take time to read the

help

you

protect

Safety precautions.

They

will

yourself against potential

hazards on the worksite. Weve

~ -~-r ~ made installation and

operation quick

and easy.

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litlilil

t With Miller you can count on years of reliable

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REGISTERED

QUALITY SYSTEM

______________ some reason the unit needs

repair,

theres a

~twc

~

Miller Is the first welding equipment manufacturer in the U.S.A.

to be registered to the iSO 9001 Quaiity

System Standard.

Troubleshooting

section that will

help

you

figure

out what the

problem

is. The

parts

list will then

help

you to decide which exact

part

you may need to fix the

problem. Warranty

and service information for your

particular

model m$z~sa~ ta~

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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

catalog

sheets.

To locate your nearest distributor call 1-800-4-A-Miller.

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Description

Call

1-800-4-A-MILLER for your local

Miller distributor.

Your distributor gives you

Service

You always get the fast, reliable response need.

Most you replacement parts can be inyourhands 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.

Patented technologyand Millers vast experience in powersourcedesign cometogetherin atrulyafford able and effective TIG package.

The Econotigfi is a full-featured machine that brings you capabilities which were previously available only with heavy duty industrial TIG equipment.

You get big machine performance from a sleek, compact package.

The Econotigs unique design and Millers innova tive engineering make a system that is incredibly easy to use.

Its an excellent choicefori,ovice users and hobbyists, but dont underestimate this machines power.

handle a wide

It has the strength arid stamina to variety of light indus~riaI welding tasks. Yet it operates off single-phase power.

The Econotig is a complete AC/DC, TIG and Stick welding package.

There are no hidden costs or ex tras to buy.

All you need is a bottle of shielding gas and some

Stick electrodes and youre ready to start welding.

Its ideal for farmers, ranchers, hobbyists and moonlighters anyone who requiresthe versa tility to handle Stick work, plus the finesse available only from the TIG process.

IntheTIG mode, the Econotigofferssuperiorperfor mance: 18 gaugeto3/1 6in (1 .2to4.8

rnm)steel and stainless steel; 14 gauge to 3/16 in aluminum (see Section 5.4).

(1.3

to 4.8

For thicker mm) metals, take advantage of the Stick mode using 3/32 and 1/8 in (2.4and

3.2

mm) electrodes.

No matterwhatlevel of skill and experience you have, the Econotig will help you be a more effective, versatile and produc tive welder.

Table of

Section

Contents

1.

Safety

Precautions

2.

Definitions

3.

Introduction

4.

Installation

5.

Operation

6.

Maintenance and

Troubleshooting

7.

Electrical

Diagram

8.

High Frequency

9.

Parts List

Options

and Accessories

Warranty

Features

AC output for superior aluminum welding

DC output for mild and stainless steel

Four-position polarity and range selector switch offers two AC current electrode ranges, DC

()forTlG, and DC electrode (+)for

Stick

Patented, built-in arc assist stabilizer for AC

TIG on aluminum

Patented, built-in arc assist starter for DC TIG

Process switch automatically sets machine for TIG or

Stick

Unique flow-through shielding gas TIG torch connection allows removal of torch without tools

Preset automatic tungsten postflow timer protects tip, workpiece and torch

Automatic high temperature shutdown

Processes

Gas Tungsten Arc

(TIG) Welding

~

Shielded Metal Arc

(Stick) Welding

The following terms are used interchangeably throughout this manual:

TIG

=

GTAW

Stick

=

SMAW

Page

19

20

22

11

12

.~ 5

18

1

9

Miller offers a

Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical

Manual, contact your local distrib utor.

Your distributor can also supply you with Welding Process

Manuals such as SMAW, GTAW,

GMAW, and GMAW-P

For practical information on weld ing, process applications, and Miller products, visit our website at www.mlflerwelds.com

Declaration of Conformity

Manufacturers Name:

Manufacturers Address:

Miller Electric

Mfg.

Co.

1635 W.

Spencer

Street

Appleton, WI

54914

USA

Declares that the

product:

E

CO

N

OT

I

(~

~

(product name) conforms to the

following

Directives and Standards:

Directives

Electromagnetic Compatibility

Directives: 89/336EEC, 92/31/EEC

Low

Voltage

Directive: 73/23/EEC

Machinery

Directives: 89/392/EEC, 91/368/EEC, 93/C 1 33/04, 93/68/EEC

Standards

Electromagnetic Compatibility (EMC)

Product standard for arc

welding equipment:

EN5O 199:

August

1995

Safety Requirements

forArc

Welding Equipment part

1: EN 60974-1: 1990

Arc

Welding Equipment

Part 1:

Welding

Power Sources: IEC 974-1

(Apr11

1995 Draft

revision)

Degrees

of Protection

provided by

Enclosures

(IP code):

IEC 529:1989

Insulation coordination for

equipment

within

low-voltage systems:

Part 1:

Principles, requirements

and tests: IEC 664-1:1992

European

Contact: dec_con 1 7/95

Telephone:

Fax:

Mr.

Luigi

Vacchini,

Managing

Director

MILLER

Europe

S.P.A.

Via Privata lseo

20098 San Giuliano

Milanese,

Italy

39(02)98290-1

39(02)98281-552

1.

Safety Precautions Read Before Using

11

Symbol Usage

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:::~:.~

OM-167 439F

-

Date, safety_som 4/97 a Means Warning!

Watch Out!

There are possible hazards with this procedure!

The possible hazards are shown in the adjoining symbols.

A Marks a special safety message.

~ Means Note~ not safety related.

~E. ~

::..

A The symbols shown below are used throughout this manual to call see the attention to and identify possible hazards. When you symbol, watch out, and follow the related instructions to avoid the hazard. The only a summary safety information given below is of the more complete safety information found in the Safety Standards listed in Section 1.4. Read and follow all Safety Standards.

A Only qualified persons should install, operate, maintain, and repair this unit.

A During operation, keep everybody, especially children, away.

r~:SHOQKcawkIIL1..2~

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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 installed or touching the welding wire are electrically live.

Incorrectly improperly grounded equipment is a hazard.

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

Do not use

AC output in damp areas, if movement is confined, or if there is a danger of falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present on unit.

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).

Properly install and ground this equipment according to its

Owners Manual and national, state, and local codes.

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.

When making input connections, attach proper grounding conductor first double-check connections.

Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

This group

ELECTRIC of symbols means Waming!

Watch Out!

possible

SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions to avoid the hazards.

:::.:.::.:..

:

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directly with a separate cable do not use work clamp or work cable.

Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

Use only well-maintained equipment. Repair or replace damaged parts at once.

Maintain unit according to manual.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to prevent contact with any metal object.

SIGNIFICANT DC VOLTAGE exists after removal of

input

power on inverters.

Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

-

~

FUMES AND GASES can be hazardous

1

=9,

Welding produces fumes and gases.

Breathing these fumes and gases can be hazardous to your health.

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

If ventilation is poor, use an approved air-supplied respirator.

Read the Material Safety Data Sheets (MSDS5) and the manufacturers instructions for metals, consumables, coatings, cleaners, and degreasers.

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 lower the oxygen level fumes and gases causing injury or can displace death.

Be air and sure the breathing air is safe.

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.

Do not weld on coated cadmium metals, such as galvanized, lead, or plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator.

The coatings and any metals containing these elements can give off toxic fumes if welded.

1

OM-167 439

2 can bum eyes and skin

Arc rays from the welding visible and invisible process

(ultraviolet produce and intense infrared) rays that can bum eyes and skin.

Sparks fly off from the weld.

Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1

listed in Safety Standards).

Wear approved safety glasses with side shields under your helmet.

Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.

VELDING can cause fire or

explosion

area

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up.

Sparks can fly oft from the welding arc.

The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal cause sparks, explosion, objects can overheating, or fire. Check and be sure the is safe before doing any welding.

Protect yourself and others from flying sparks and hot metal.

Do not weld where flying sparks can strike flammable material.

Remove all flammables within 35 ft (10.7 m) of the welding arc.

If this is not possible, tightly cover them with approved covers.

Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.i

(see

Safety Standards).

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 and fire hazards.

Do not use welder to thaw frozen pipes.

Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

FLY~NGMETM~fl!fljurغ~~

Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

Wear approved safety glasses with side shields even under your welding helmet.

Shutoff shielding gas supply when not in use.

Always ventilate confined spaces or use approved air-supplied respirator.

.HOTPARTS

can:: au~

Do not touch hot parts bare handed.

Allow cooling period before working on gun or torch.

___________

MAGNETIC FIELDS can affect

pac~makers~

Pacemaker wearers keep away.

Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

NOISEcan~maeh~~

Noise from some damage hearing.

processes or equipment can

Wear approved ear protection if noise level is high.

CYLiNDERScanex~Iodefda~e~J

Shielding gas cylinders contain gas under high pressure.

Since gas

If damaged, cylinders are a cylinder normally part can of the explode.

welding process, be sure to treat them carefully.

Protect compressed gas mechanical shocks, slag, cylinders open flames, from sparks, excessive and arcs.

heat,

Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder explosion will result.

Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is in use or connected for use.

Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-i listed in Safety

Standards.

OM-i67 439

1~~dditiq~aI

Syi~o1ifcr-$nstÆHation;.Op~ritIon,and~

MinienancŁ~.

~--~

----

~-

Do not install or place unit on, over, or near combustible surfaces.

Do not install unit near flammables.

Do not overload building wiring be sure power supply system is properly sized, rated, and protected to handle this unit.

)VtNG.~-PARTScancatiŁeinjr~.

Keep away from moving parts such as fans.

Keep all doors, panels, covers, and guards closed and securely in place.

j

PALUNG UNIT can cause injury

Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

Use equipment of adequate capacityto lift and support unit.

If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause

OVERHEATING

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle before starting to weld again.

Do not block or filter airflow to unit.

-HFRADiOF~Ænc~se1nterte$nce.I

S

S

High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

Have only qualified persons familiar with electronic equipment perform this installation.

The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

If notified by the FCC about interference, stop using the equipment at once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

(ESD)

can

damage

PC boards

S

S

Put on grounded wrist strap BEFORE handling boards or parts.

Use proper static-proof bags and boxes to store, move, or ship PC boards.

PARTS can cause

Injury

Keep away from moving parts.

Keep away from pinch points such as drive rolls.

~

-~:r~-~

~ can cause

Interference

~-~~

Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots.

Be sure all equipment in the welding area is electromagnetically compatible.

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec tronic equipment.

Be sure this welding machine is installed and grounded according to this manual.

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.

WELDING WIRE can cause

Injury

Do not press gun trigger until instructed to do so.

Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

Pdnc.ip.~J$a~ety~tan

dards

~-

-....

-.~

~

~-

Safety in Weld,ng and Cutting, ANSI Standard Z49.

1, from American

Welding Society, 550 N.W.

LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten dent of Documents, U.S. Government Printing Office, Washington,

D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and

Cutting of Containers That Have Held Hazardous Substances,

American Welding Society Standard AWS F4.1, from American

Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

~

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-i, from Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1 R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51 B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1

3

OM-i67 439

k

5 EMF Infrmat~on

~

.

~

.

Considerations About

Electric And

Welding And The Effects Of Low Frequency

Magnetic Fields

The following is a quotation from the General Conclusions Section of the U.S.

Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields Background

Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing

Office, May 1989):..

.

there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems.

While most of this work is of very high quality, the results are complex.

Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework.

Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.

.:~.

~

I

\

~

To reduce procedures: magnetic fields in the workplace, use the following

1.

Keep cables close together by twisting or taping them.

2.

Arrange cables to one side and away from the operator.

3 Do not coil or drape cables around the bod

4.

Keep welding power source and cables as far away from operator as practical.

5.

Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

The above wearers.

procedures are also recommended for pacemaker

Consult your doctor for complete information.

4

OM-167 439

1.

Consignes do sØcuritØ lire

avant

utilisation

~

~1 1

a

~ .~ y;:~~

Signification

des

symboles

Signifie Mise en garde! Soyez vigilant!

Cette procedure presente des risques de danger!

Ceux-ci sont identifis par des symboles adjacents aux directives.

r???.~q~~

A Identifie un message de sØcuritØ particulier.

Ce groupe de symboles signifie Mise en garde I Soyez vigilant lily a des risques do danger relies aux

CHOCS

ELECTRIQUES, aux

PIECES

EN

MOUVEMENT etaux

PIECES

CHAUDES.

Reportez-vous aux symboles et aux directives ci-dossous af in de connaltre los mesures a prendre pour

Øviter tout danger.

lI~ Signifie NOTA nest pas relatif Ia sØcuritO.

1 2

Dangers

relatifs

au

soudage

a Iarc

A Lea symboles presentØs ci-apres sont utilisØs tout au long du present manuel pour attirer votre attention et identifier lea risques do danger. Lorsque vous voyez un symbole, soyez vigilant et suivez lea directives mentionnØes at in dØviter tout danger.

Lea consignee de sØcuritØ prØsentees ci-aprea ne font que rØsumer linformation contenue dana lea normes de sØcuritØ

ØnumØrØes a Ia section 1-5.

Veuillez lire et respecter toutes ces normes do sØcuritØ.

A Linstallation, lutilisation, lentretien et lea reparations no doi vent ºtre confiØs qua des personnes qualifiees.

A Au cours do lutilisation, tenir touts personne Ł lØcart et plus par ticuliŁrement lea enfants.

UN CHOC

ELECTRIQUE petit

tuer~

Un simple contact avec des piŁces electriques pout provoquer une electrocution ou dos blessures graves.

LØlectrode et le circuit de soudage sont sous tension des quo lappareil est sur

ON. Le circuit dentrŁe et les circuits intemes de lappareil sont egalement sous tension ace moment-l.

En le fit, Is dØvidoir, le soudage semi-automatique ou automatiquo, logement des galets dentraInement sties piŁces metalliques en contact avec le f II do soudage sont sous tension.

Des matØriels mal installØs ou mal mis a Ia terre prØsentent un danger.

Ne jamais toucher los piŁces electnques sous tension.

Porter des gants pas de trous.

et des vŒtements do protection secs ne comportant

Sisoler de Ia piŁce et de Ia terre au moyen de tapis ou dautres moyens isolants suftisamment grands pour empecher Is contact phy sique Øventuel avec

Ia piŁce ou

Ia terre.

Ne passe servirde source electnque courant electrique dans les humides, dans los endroits confines ou l o on risque de tomber.

zones

Se servir dune source electrique courant electnque UNIQUEMENT Si le procØde de soudage le demande.

Si lutilisation dune source electrique courant electnque savŁre nØces saire, se servir de Ia fonction de tOlØcommande si lappareil en est Oquipe.

Couper lalimentation ou arrOter le moteur avant do procØder linstal lation, a Ia reparation ou a lentrotien do lapparoil.

lalimentation selon Ia norme

OSHA 29 CFR 1910.147

DØverrouiller

(voir normes de sØcuritØ).

Installeret mettre ala terre correctement cet apparoil conformOment a son manuel dutilisation et aux codes nationaux, provinciaux et municipaux.

Toujours verifier Ia terre du cordon dalimentation Verifier et sassu rer que le fil de terre du cordon dalimentation est bien raccordØ a Ia borne do terre du sectionneurou que a une pnse correctement

Ia fiche du cordon est raccordØe mise a Ia terre.

En effectuant les raccordements dentrØe fixer dabord 10 conducteur do mise a Ia terre approprie et contre-vØnfier los connexions.

Verifier frequemment le cordon dalimentation pour voir sil nest pas endommage ou dŁnudØ romplacer le cordon immØdiatement sil est endommage un cable dØnud pout provoquer une dlectrocution.

Mettre lappareil hors tension quand on no lutilise pas.

Ne pas utiliser des cables sante ou mal Opisss.

uses, endommages, do grosseur insuffi

Ne pas enrouler los cables autour du corps.

Si (a piŁce soudØe doit Œtre mise ala terre, 10 faire diroctement avec un cable distinct no pas utiliser lo con necteur do piŁce ou lo cable do retour.

Ne pas toucher lØlectrode terre ou une electrode quand provenant on est dune en contact autre avec machine.

Ia piŁce, Ia

OM-167 439

Nutiliser quun materiel en bon Øtat.

ROparor ou romplacer sur-le champ les piŁces endommagees.

Entretenir lappareil conformŁment

~ ce manuel.

Porter un hamais do sOcuritØ quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Fixer le cable do retour de tacon a obtenir un bon contact mØtal-mOtal avec

Ia piŁce a souder ou

Ia table de travail, le plus prŁs possible do Ia soudure.

Ranger et isoler correctoment Ia pince de masse aprŁs utilisation pour

Øviter le contact avec des objets relies a Ia masse.

Ily

a

DU COU RANT CONTINU IMPORTANT dans les convertisseurs

aprŁs

Ia

suppression

de Ialimenta tion

electrique.

ArrOtor los convertisseurs, dØbrancher le courant eloctrique, et de charger les condensateurs dalimentation selon los instructions indiquees dans Ia partie entretien avant do toucher les piŁces.

___.__I._I

I

=9

J

Le~ inhalation pout Otre desL..............

dangoroux pour v....

~.

_____________

Eloigner votre tŒte des fumŁes. No pas rospirer los fumØes.

A lintØneur, ventiler Ia zone etlou utiliser un veau de Iarc pour echappement au ni lØvacuation des fumØes ot des gaz do soudage.

Si Ia ventilation est tion dair insuffisante, utiliser un respirateur a alimenta homologue.

Lire los specifications do sØcuritØ des matØriaux (MSDSs) et los ins tructions du los fabricant concernant los mØtaux, los consommables, revØtements, les nettoyants ot los degraissours.

Travaillor dans en portant un un espace fermØ seulement siI est bien ventilØ ou rospirateur a alimentation dair.

Demander toujours a un surveillant dOment formØ do so tonir a proximitØ.

Des fumØes of des gaz de soudage peuvent dØplacer lair et abaisser 10 nivoau doxygene provoquant des blessures ou des accidents mortols.

Sassurer quo lair do respiration ne prØsente aucun danger.

Ne pas souderdans des endroits situØs ~ proximite dopOrations do degraissage, do nottoyage ou do pulvØrisation.

La chaleur et los rayons do larc des peuvent gaz hautoment reagir toxiques en presence et irritants.

do vapours ot former

No pas soudor dos mØtaux munis dun revØtement, tels quo lacier galvanise, plaque en p10mb ou au cadmium a moms quo 10 revOte mont nait ØtØ onlovØ dans Ia zone de soudure, quo lendroit soit bion vonti!Ø, of si nOcossairo, on portant un respirateur a alimonta tion dair.

Los revOtoments et tous los mØtaux ronformant ces

Ole monts pouvont degagor des fumOes toxiques en cas do soudago.

1t~

5

6 voquer des brOlures clans les

surIapeau~

yeux et

Le rayonnoment de larc du procdØ do soudago gØnŁro dos rayons visiblos et

(ultraviolets ot infrarougos) invisiblos intenses suscoptiblos do provoquor des brluros dana los youx et sur

Ia peau.

Des Øtincelles sont projetØes pendant le soudage.

Porter un casque do soudago muni dun Ocran do filtro appropriO pour protager votro visage et vos youx pondant le soudage ou pour regar der (voir ANSI Z49.

1 et Z87.1 OnumØrØ dans les normes do sØcuritØ).

Porter des protections approuves pour les oreilles Si le niveau sondre eat trop ØlevØ.

Utiliser des Øcrans ou des barriŁres pour et do leblouissement; demander aux protØger autres des tiers do Øclair personnes done pas re garder larc.

Porter des vØtements do ble, resistant au feu (cuir protection constituØ dans une matiOro dura ou lame) et une protection des pieds.

~

LE

SOUDAGE~~tut provoquerun:

incendleou une

expIoslon~

Le soudage effectuO sur des conteneurs fermØs tels quo des reservoirs, tambours ou des conduites peut provoquerleureclatement.

Des Øtincolles pouvent Otre projetØes do larc do soudure. La projection dOtincel los, dos piŁces chaudes et des equipemonts chauds pout provoquer des incondies ot des brOlures. Le contact accidontel do lOlectrode avec des objets metalliques pout provoquer des Øtincelles, une explosion, surchauffemont ou un incondie.

Avant do commencer le un soudage, verifier et sassuror quo lendroit no prØsento pas do danger.

So proteger ot dautres personnes do Ia projection metal chaud.

dOtincelles et do

Ne pas sur souder dana un endroit l des substances inflammables.

oU dos Otincellos pouvont tomber

DØplacertoutos los substances inflammables a uno distance do 10,7 m do larc do soudago.

mont avec dos

En cas dimpossibilitØ los recouvrir soigneuso protections homologues.

Des Otincelles et dos matØriaux chauds du soudage peuvent facilemont passer dans des ouvorturos.

dautres zones en traversant do petites fissures ot

SurveillertoutdØclenchementdincondio mite.

ottonirunoxtincteuraproxi

Le soudago effectuO sur un plafond, plancher, paroi ou separation pout dØclencher un incondie do lautre ctØ.

Ne pas offectuer 10 soudago sur des contoneurs reservoirs, tambours, ou conduites, a moms quils fermŁs tels quo dos naiont etO prØpa rØs corroctemont conformØmont a AWS F4.1

(voir los normes do securite).

Branchor le cable sur

Ia piŁce 10 plus pres possible do Ia zone do sou dage pour Cviter

10 transport du courant sur une longue distance par dos chomins inconnus Øvontuols en provoquant dos risquos dØloc trocution et dincendie.

No pas utiliser le lees.

poste do soudage pour degolor dos conduitos go

En cas do non electrode ou utilisation, enlevor Ia couper 10 fil a Ia baguette dØlectrode du porte pointe do contact.

Porter des vŒtemonts do protection depourvus dhuilo tels quo des gants on cuir, une chemise en matØnau lourd, des vors, dos chaussures hautes ot un couvro chef.

pantalons sans re

Avant do tollos souder, retirer toute substance combustible do vos poches quun allumeur au butane ou dos allumettes.

~~RTICULESVOLANTES..

des Øtincellos ot dos particules metalliques volan tes. Pendant Ia periodo do ref roidissomont des soudures, ollos risquont do projeter du laitier.

Lo soudago, lØcailloment, le passage do Ia piŁce a Ia brosso en fil do fer, ot le moulago generont

Porter des lunettos do sØcuritØ avec

Øcrans latØraux ou Un

Øcran facial.

C~J

Former lalimentatlon du gaz non utilisation.

protecteur en cas de

Veillertoujours a blon aØrorles espaces confines ou Se servir dun respl rateur dadduction dalr homologue.

_______

I DES

PIEqES~CHAUDE$peuvent

pro

voquerdes ~

j

No pas toucher dos nues parties chaudos a mains

PrØvoir une dutiliser le pØriodo do refroidissoment avant pistolet ou

Ia torche.

peUvent

sUmulateurs cardiaques

Porteursdestimulateurcardiaque, restez distance.

Los porteurs dun stimulateur cardiaque dabord consulter leur mØdecin avant de doivent sapprocher des operations de do soudage par soudage points.

a larc, de gougeage ou

LEkBRUITPeUt affectØ~r

Powe .

_______________

Lo bruit des processus et des equipoments peut affecter

IouIe.

Porter des protections approuvØs pour los oreilles 51 lo nivoau sondre est trop ØlevØ.

~SIdes

qØes,

~

eIiespourro~ipj~e~_

Des boutoillos do gaz sous haute prossion.

protecteur

Si uno contiennent boutoille est du gaz endomma gee, 0110 pout oxploser.

font normalement

Du fait quotes bouteilles do gaz partie du procØde do soudago, los manipuler avec precaution.

Protegor los bouteillos de gaz compnmŁ dune chaleur excessive, des chocs mecaniques, du laitier, dos flammes ouvortes, des Øtin cellos et dos arcs.

Placer los boutoillos nairo ou dans un debout en los fixant dans un support station porte-bouteilles pour los empØcher do tomber ou do so renverser.

Tenir los boutoilles eloignees dos circuits do soudage ou autres cir cuits eloctriques.

No jamais placer une torche do soudago sur uno boutoille a gaz.

Uno electrode do une bouteillo.

soudage ne doit jamais ontrer en contact avec

No jamais souder uno bouteille pressurisee risque doxplosion.

Utilisor seulement des bouteilles do gaz protocteur, rOgulatours, tuyaux et raccords convonablos pour cette application specifique; los maintonir ainsi quo los ØlØmonts associØs en bon Øtat.

No pas tenir Ia boutoillo.

tŒte on face do Ia sortie en ouvrant Ia soupape do Ia

Maintenir le chapeau do protection sur

Ia soupapo, sauf en cas dutilisation ou do branchement do Ia bouteille.

Lire et suivro los instructions concemant los bouteilles do gaz cornprime, los equipements associØs et los publications P-i CGA Ønu mØrØes dans los normes do sØcuritØ.

OM-167 439

t 3

Dangers supplØmentaires

etlamainfenance

en

relation

aitec

rinstallation, le

iu~n~ima

:~

~1

1__~J

DES ORGANES

MOBILES

peu~i

Ne pas placer lappareil sur, au-dessus proximitO de surfaces infliammables.

ou a

Ne pas installer lappareil a proximitØ de produits inflammables

Ne pas surcharger linstallation Ølectrique tation est correctement dimensionnØ et sassurer protØgØ que lalimen avant de mettre lappareil en service.

DAREIL

peut

Utiliser lanneau de levage uniquement pour sou lever lappareil, NON PAS les chariot, les bouteil les de gaz ou tout autre accessoire.

Utiliser un engin dune capacitØ appropriee pour soulever lappareil.

En utilisant des fourches de que les fourches sont oppose de lappareil.

levage pour deplacer lunitØ, sassurer suffisamment longues pour depasser du cafØ

LEMPLOI EXCESSIF

peut

SURCHAUFFERLEQUIPEM

ENt

PrOvoir une ter le pOriode de ref roidissement, cycle opOratoire nominal.

respec

Reduire le courant ou le cycle opOratoire avant de recommancer le soudage.

Ne pas obstruer les passages dair du poste.

-~

HARGES

ELEItbsT ATIQUS itenornmager

Ies.cfrcu Its

!.

Etablir

Ia connexion avant de avec

Ia barrette de terre manipuler des cartes ou des piŁces.

Utiliser des pochettes et des boltes antistatiques pour stocker, dØplacer ou expOdier des cartes de circuits imprimes.

:s ORGANES MOBILES

YP~q

peuvent

4es

bies es

i:

Ne pas sapprocher des organes mobiles.

Ne pas sapprocher des points de coincement tels que des rouleaux de commande.

::tES~nLS0ESQUbAGE

peuvent

pro

~..voq!ft~s blessures.

No pas appuyer sur Ia reu linstruction.

gachette avant den avoir

Ne pas diriger le pistolet vers soi, dautres per sonnes ou toute piŁce mecanique en engageant le fil de soudage.

Rester a lecart des organes mobiles comme le vent ilafeur.

Maintenir fermes et fixement en place les portes, panneaux, protection.

recouvrements et dispositifs de

LE

RAVONNEMENt~ HAUTE~YFRE-:

OUENCE4H F) risque

de provoquer de

SM t$reSES

:.*HY:~*J

Le rayonnement haute frequence des interferences avec les peut provoquer

Øquipements de ra dionavigation et de communication, es services de sOcurite of les ordinateurs.

Demander seulement a des personnes avec des equipements Olectroniques de qualifiees familiarisees faire fonctionner linstalla tion.

Lutilisateur est tenu de faire corriger rapidement qualifiO los interferences resultant de linstallation.

par un electricien

Si le FCC signale des interferences, arrOter immØdiatement lappa reil.

Effectuer reguliŁrement le controle et lentretien de linstallation.

Maintenir soigneusement fermes les portes et les panneaux des sources de haute frequence, maintenir les Łclateurs a une distance correcte et utiliser une terre et et un blindage pour rOduire les inter ferences eventuelles.

de.

Lenergie electromagnetique risque de provoquer des interferences pour lequipement electronique sensible tel que les ordinateurs et lequipement commande par ordinateur tel que los robots.

Veiller ace que tout lequipement de Ia zone de soudage soit com patible electromagnetiquement.

Pour reduire Ia possibilite dinterference, maintenir les cables de soudage bas que aussi courts que possible, les grouper, et los poser aussi possible (ox.

par terre).

Veiller a souder a une distance de 100 metres de tout electronique sensible.

equipement

Veiller a ce que ce poste conformement a ce mode de soudage demploi.

soit pose et mis a Ia terre

En cas dinterferences apres avoir pris les mesures precØdentes, il incombe a lutilisateur de prendre des mesures supplØmentaires telles que le deplacement lutilisation de filtres de du ligne poste, ou Ia lutilisation pose de de cables protecteurs blindes, dans Ia zone de travail.

:St!piUIathi4r~cardlaques;

Porteurs de stimulateur cardiaque, restez a dis tance.

Les porteurs dun stimulateur cardiaque doivent dabord consulter leur mOdecin avant de sappro cher des geage ou operations de soudage a larc, de gou de soudage par points.

7

OM-167 439

A

Principales

normes

iesØcuritØ

Safetyin Welding and Cutting, norme

ANSI Z49.1, de lAmerican Wel ding Society, 550 N.W.

Lojeuno Rd, Miami FL 33126

Safetyand Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances, norme

AWS F4.1

, de lAmerican Welding Society, 550 N.W.

Lejeune Rd, Mia mi FL 33126

National Electrical Code, NFPA Standard 70, de Ia National Fire Pro tection Association, Battorymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High way, Suite

501, Arlington, VA 22202.

Regles de sØcuritØ en soudage, coupage etprocOdOs connexes, norme

CSA Wi 17.2, de lAssociation canadienne de normalisation, vente de normes,

1R3.

178 Roxdale Boulevard, Rexdale (Ontario) Canada M9W

Safe Practices For Occupation And Educational Eye And Face Protec tion, norme

ANSI Z87.i, de lAmerican National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme

NFPA SiB, de Ia National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1

5 information suries

champs electromagFnetlques

DonnØes sur le des soudage electrique et sur les effots, pour lorganisme, champs magnØtiques basso frØquence

Loxtrait suivant est tire des conclusions generales du document intitu

6 Biological Effects of Power Frequency Electric & Magnetic Fields

Background Paper, OTABPE53 ment

(Washington DC: U.S. Govern

Printing Office, mai 1989), publiØ par le Office of

Technology

Assessment du dantes donnOes

Congres amØricain:

...

1 existe maintenant dabon scientifiques compilØos a Ia suite dexpØriences sur

Ia cellule ou dØtudes sur des animaux et des humains, qui montrent clairement quo los champs Ølectromagnetiques basso frOquenco peu vent avoir des transformations.

offets sur

MŒme sil lorganisme et memo y produire des sagitde travaux de trØs grande qualitØ, les rØsultats sont complexes.

Cette dØmarche scientifique ne nous permet pas dØtablir un tableau densemble coherent. Pire encore, elle ne nous permet pas de tirer des conclusions finales concernant les ris ques

Øventuels, ni doffrir des consoils sur los mesures a prendro pour rØduire sinon Øliminer los risques Øventuels.

(Traduction Iibre)

2

3

Afin do rØduire les champs electromagnetiques dans lenvironnemont de travail, respecter los consignos suivantes

1 Garder los cables ensembles en los torsadant ou en los attachant avec du ruban adhOsif.

4

Mottro tous los cables du ctØ oppose do lopØratour.

Ne pas courber pas et no pas entourer pas los cables autour do vous.

Garder le poste de de vous.

soudage et los cables le plus loin possible

5 Relier Ia pinco do masse lo plus prŁs possible de Ia zone do soudure.

Consignes relatives aux stimulateurs cardiaques

Les consignes mentionnØes precedemment font partio de celles desti nØos aux personnes ayant rocours a un

Veuillez consulter votro mØdecin pour obtonir stimulateur plus cardiaquo.

do details.

8

OM-167 439

2. Definitions

2 1 Generat

Precautionary

Label

~

Warning!

Watch Out!

There are possible hazards as shown by the symbols.

1 Electric shock from welding electrode or wiring can kill.

1.1

Wear dry insulating gloves.

Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

1 .2 Protect yourself from electric shock by insulating yourself from work and ground.

1.3

Disconnect input power before machine.

plug or working on

2 Breathing welding fumes can be hazardous to your health.

2.1

Keep your head out of the fumes.

2.2

Use forced ventilation or local exhaust to remove the fumes.

2.3 Use ventilating fan to remove fumes.

3

3.1

Welding sparks can cause explosion or fire.

Keep flammables away from welding.

Do not weld near flammables.

3.2

Welding sparks can cause fires.

Have a fire extinguisher nearby, and have a watchperson ready to use it.

3.3

Do not weld on drums or any closed containers.

4

4.1

Wear hat and safety glasses.

Use ear protection and button shirt collar. Use welding helmet with correct shade of filter.

Wear complete body protection.

5

Arc rays can burn eyes and injure skin.

6

Become trained and read the instructions before working on the machine or welding.

Do not remove or paint over

(cover) the label.

OM-167 439

1/96

9

2 2~ ~Manufaotu~rers

Rating

Labels

380 Volt Models

EN 60974-1

20A/1 0.8V

180 All 7V

30A/11.2V

165Al16.6V

20A/20.8V

1 70A/26.8V

30A121.2V

135A/25.4V

1T1_1T11

415 Volt Models

EN 60974-1

20A/1 0.8V

1 80A11 7V

30A/1 1 .2V

1 65A/1 6.6V

20A/20.8V

1 70A/26.8V

30A/21 .2V

135A/25.4V

Ui 380V imax

IP 23

44A left 16A U1 415V imax

IP 23

40A left 15A

2~3:.

SymhotDefinitions~.

10

Tig Welding

~It~

Remote Footl

Hand Control

3...

Output

~\J~

Alternating Current

+

A

...

Electrode Positive

Electrode

Negative

,

A

Amperes

~J

Off

Amperage Control/

Panel

U

0

Rated No Load

Voltage (Average)

I

1

max

Rated Maximum

Supply Current

Percent

Work

Stick Welding

Direct Current

/

Do Not Switch

Under Load

Electrode

Remote

(~3.*

~(

High Temperature

On

Voltage Input

Gas Out

Volts

U2

Conventional Load

Voltage

2

Rated Welding

Current

U1

Primary Voltage

X

Duty Cycle

Degree Of

Protection

left

Maximum Effective

Supply Current

Single-Phase

Combined AC/DC

Power Source

~J

~ Line Connection liz

Hertz

OM-167 439

3. Introduction

~3 1 Included with Your Unit

1

2

3

4

5

6

7

8

12 ft (3.7 m) Work Cable and Clamp

150 Amp TIG Torch with

12-1/2 ft (3.8 m) Cord and

Flow-Through Quick-Con nect (50 Hz models come with 25 ft (7.6 m) TIG

Torch)

Electrode Holder and

Quick-Connect

Gas Hose

Gas Regulator (Not included with 50 Hz mod els)

How-To Videotape

Foot Control with 20 ft m) Cord (60 Hz models

(6 only.

50 Hz and applicable other models come with

Fingertip Control instead.)

8 ft (2.4

m) Primary Cord

(Plug supplied with 230

Volt model only) fT Some assembly is required.

For options and accessories see back of book or contact your distributor.

132

SpecificatIons~

Rated Output at 20%

Duty Cycle

T(G: 15OAat15VDC

(GTAW) 15OAat15VAC

Stick: 130 A at 25 VDC

(SMAW) 150 A at 25 VAC

While idling.

Welding Amperage Range

AC High AC Low DC

TIG Welding A Range

50165 2050 30160

Stick

35165

Welding A Range

2050 25130

Max,~

Open-Circuit

Voltage

78

Rated Output

380 V-39 A

415V36 A

78

KVA

14.8

0.64

Dimensions

H: 18 in (457 mm)

W: 13 in (330 mm)

D: 251/2 in (648 mm)

Net

Weight

140 lb

(64 kg)

Duty Cycle

Chart

~

----~.

-~:~

0

100

Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

A Exceeding duty cycle can damage unit and void warranty.

-~

...:.

-.

\

ST:157648.A

GTAW: 20% Duty Cycle at 150 A AC/DC

SMAW: 20% Duty Cycle at 130 A DC, or

150 A AC

10 II x

SO 40 50

DUTY CYCLE

IO~SOIO~0

2 Minutes

Welding

8 Minutes

Resting

11

OM-167 439

:~i.

Volt-Ampere

-::v

Curves

Volt-ampere curves show mini mum and maximum voltage and amperage output capabilities of welding power source.

Curves of other settings fall between curves shown.

U,

70 t

0

60

20

0

~\

\ r\

I

1C

\\

I>\ A

\i i1I

50

A

:L~0w

RANX

RAh~

~ tO

~

150

AC APvFERES

I

2(X)

I

250 3W

.:Y~ .~ nr .~T~VtflrrqT$rrt~~ ssbl.1

10/91

___

ST-157 625-B / ST-157 626-B

J

70

80

~2w

~40

Sr

ZJ

10

0

0 50 100 150

DC AMPERES

2W 250 3W

4.

Installation

4 1

-

Selecting

a

Location

:.~iL~i

-~

.

~

~

Position unit so air can circulate.

For information aboutsources of high-frequency see

Section 8.

For carts and caster kits see back of book or contact your distributor.

az

-a:.~)::L~:~~-...a

18 in

(460 mm)

ST-158 075

18 in

(460 mm)

42

tar .~ a

Typical

~ arrzI~rrt~~

StlcI

Connections

:a..::.~

1 Electrode Holder

2 Work Clamp

Connect to receptacle as shown.

1

.:...

.:

-:~~---.

a:-:~ ----~tr

ST-157 858-A

12

OM-167 439

i~3

Typical

TIG Connections

~

~

1 Remote Control

2 Torch

3 Work Clamp

Connect to receptacle as shown.

4 Cylinder

Chain or secure cylinder to running gear, wall, support.

or other stationary

5 Cylinder Valve

Open valve slightly so gas flow blows dirt from valve. Close valve.

6 Regulator/Flow Gauge

Install so face is vertical.

7 Flow Adjust

Typical flow rate is 20 cfh (cubic feet per hour) (9.4

L/min).

3

OM-167 439

Ref.

ST157 858-A

Tools Needed:

5/8,1-1/Bin

13

4~4 ElectricalServuce Guide

Input Voltage

Input Amperes at Rated Output

Standard Fuse or

Circuit Breaker Rating

(Max. Recommended)

Input Conductor Size (Mm.)

Input Conductor Length (Max. Recommended)

Grounding Conductor Size (Mm.)

Reference: 1996 National Electrical Code (NEC).

~4 5

Connecting Input

Power

A Have only qualified persons make this installation.

A Special installation may be required where gasoline or volatile liquids are present see

NEC Article 511 or

CEC

Section 20.

Units come equipped with input power cord for installation into line disconnect device. Select type and size overcurrent protection using

Section 4.4.

380

39

60 Amps

12 AWG

151 ft (46 m)

12 AWG

415

36

50 Amps

12 AWG

181 ft (55 m)

12 AWG

S-0092J

L2

GND/PE

14

OM-167 439

8

7

OM-167 439

5.

Operation

-\

~TSii~II1

Ref. ST-173 373-B

1 Weld Process Switch

Use switch to select weld process.

In Stick and position (down), weld output goes On

Off with Power switch.

In GTAW (TIG) position (up), remote control device turns on and adjusts weld output of unit as limited by Amperage control. Built-in arc starter comes on when needed to start or sta bilize welding arc.

No adjustments needed for arc starter.

2 Pilot Light

Power Switch 3

Use switch to turn unit, fan, and pilot light On and Off.

4 Amperage Control

For Stick perage

(SMAW), use control to adjust am within range sel3cted by the Range/

Polarity Switch.

5 Stick (SMAW) Table

Use table to find output at approximate Stick amperage

Amperage control setting.

See Section 5.2 for exarr pie of front panel am perage control.

For remote amperage control used when TIG

(GTAW) welding, front panel Amperage con trol setting is the maximum amperage percen tage available at the remote control device.

See Section 5.3 for exarr pIe of remote amper age control.

6 Range/Polarity Switch

Use switch to select range and output.

polarity of weld

For Direct Current Electrode Negative

(DCEN), use

Electrode Negative position.

For Direct Current Electrode Positive (DCEP), use

Electrode Positive position.

For alternating current (AC), use range need ed for welding application AC Low or

AC

High position see

Warning.

See Section 5.4

to find suggested type of weld output for application.

7 High Temperature Shutdown Light

Lights when unit overheats and shuts down

(see Section 6.2).

8 Output On (Contactor) Light

Lights when output (contactor) and unit power are on.

2

3

S

!.

N

$0

40

10

SO

10

$0

SO

100

~

AMPERP~ VS. D~*L%

LOW DC

$

II

$4

21

$2

$7

4$

50

I~U~l

$4

24

24

40

24

71

~4

~I

III

22

24

24

23

4$

$4

U

I~

5

4

15

16

52

Exampe

ofFronl Panel

Amperage

Control

0

\., 18-50A

34$

VS

60

Xe

0

A

100%

____

Select weld process.

Select range and polarity.

Exampe

of Remote

Amperage

Control

o

\ila-50A

I

3~1~

~.

Select percentage.

~MA~ OU~UT

AMPERP~ YB.

DIAL X

AC LOW AC HS~I f

DC Z

~ii

23 IS

IS 39 24

21 46 25 i~

24 69

80

~

~

10

27

82

31

43

60

79

~4

151

156

43

U

55

113

In Example:

Range

=

DC

Percentage of Range

=

50%

Weld Amperage

=

33 A DC

]

60

20

Xe

Select weld process.

Select range and polarity.

..........)

Select percentage.

.....14

or

-,

GTAW Welding Amperage Range

AC Low AC High DC

20-50A 60-165A 30-165A

In Example:

Range

=

DCEN

Percentage of Range

=

50%

Remote weld amperage =

3098 A DC

(50% of 30165 A DC)

Connect remote control (see Section 4.3).

OM-167 439

5~4

Pi~cess

and Material Thickness Guide Label

N

Material And

Weld Output

Steel Or Stainless Steel

()

Sl.

A

DCEN

ELECTRODE

NEGA11VE

Guideline For Welding Process And Output For Material

22 ga

0.033

in

0.8

mm

20 ga

0.036

in

0.9

mm

18 ga

0.048 in

1.2

mm

16 ga

0.06 in

1.5

mm

Material Thickness

14 ga

0.07 in

1.8

mm

12 ga

0.1

in

2.5

mm

11 ga

0.125

in

3.2

mm

10 ga

0.14

in

3.6

mm

6 ga

0.186 in

4.8

mm

2 ga

0.25 in

6.3

mm

0.25+ in

6.3+ mm

SMAW

GTAW

.

With DCEP

Output

~ ~

Aluminum

Difficult Recommended

AC

S-167 338

OM-167 439

17

G.

Maintenance and TroubleshootiNg

61 Routine

Maintenance

A Disconnect power before maintaining.

~ Maintain more often during severe conditions.

S

~

3 Months

Clean and tighten weld terminals.

Replace unreadable labels.

Replace 0-ring ~fl Electrode/Gas

Output receptacle if cracked.

6 Months

Blow out or vacuum inside.

62

Troubleshooting

Or

Trouble

No weld output; fan does not run.

No weld output; fan on.

Fan not operating; weld output available.

Remedy

Place line disconnect switch in On position (see Section 4.5).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4.5).

Check for proper input power connections

(see Section 4.5).

Be sure Range/Polarity switch is not set between positions.

Tighten remote control connection to Remote 14 receptacle.

Check remote control (see remote control Owners Manual).

Unit overheated. Allow unit to cool (see Section 3.3).

Check for and remove anything blocking fan movement.

Have Factory Authorized Service Agent check fan motor.

18

OM-167 439

7.

Electrical Diagram

71

~

Circuit

~rrs~~?:::::::::.::.:.~:

Diagram

~C..................:....

.szna~

~ DTr., ~1

SB-154 141-C

OM-167 439

230 VAC

19

20

8.

High Frequency

81

WeIdin~P~oceSs~Requiring~.Hi

high_freql 11/96 S-0693

1

1 High-Frequency Voltage

Helps arc jump air gap between torch and workpiece and/or stabilize the arc.

TIG

8~2 Incorrect Installation,

2

3

4

5

6

Sources of Direct High-Frequency

Radiation

1 High-Frequency Source (welding power source with built-in HF or unit)

Torch

Work Clamp

Workpiece

Work Table

Sources of Conduction of High

Frequency

7

8

Input Power Cable

Line Disconnect Device

9 Input Supply Wiring

~-------

Weld

--~

Zone

5Ott

(15

(I

/1

N.

N.

Sources of Reradiation of High

Frequency

10

11

Ungrounded Metal Objects

Lighting

12

14

Wiring

13 Water Pipes and Fixtures

External Phone and Power Lines

S-0694

N

7

OM-167 439

Correct Installation

.:..

~

..

.:

Ret S-0695 I Ret S-0695

1 High-Frequency Source (welding power source with built-in HF or separate HF unit)

Ground metal machine case, work terminal, line disconnect device, output input supply, and worktable.

2 Center Point of Welding Zone

Midpoint between and welding torch.

high-frequency source

3 Welding Zone

A circle 50 ft (15 m) from center point in all directions.

4 Weld Output Cables

Keep cables short and close together.

5

Electrically join (bond) all conduit sections using copper straps or conduit every 50 ft braided wire. Ground

(15 rn).

6

Conduit Joint Bonding and Grounding

Water Pipes and Fixtures

Ground water pipes every SOft

(15 m).

7 External Power or lŁlephone Lines

Locate high-frequency

~ource at least 50 ft

(15 m) away from power and phone lines.

8 Grounding Rod

Consult the National Electrical Code for specifications.

Metal Building Requirements

9 Metal Building Panel Bonding Methods

Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame.

10 Windows and Doorways

Cover all windows and doorways with grounded copper screen of not more than 1/4 in (6.4 mm) mesh.

11 Overhead Door Track

Ground the track.

Weld Zone

~

OM-167 439

________

Metal Building

21

~oc~

_.L

~) ~

13

1<

10

9

8

5

26

48

II

38

36

CI) 0

CO.

CD >

Item

No.

Dia.

Mkgs.

Part

No.

DescriDtion

1

2

13

14

15

17

154 335...

176254...

+165 986...

BEZEL, front

LABEL,

warning general precautionary

WRAPPER 3

4

5

6

7

8

9

10

11

....

PCi

....

186 172...

CIRCUIT CARD, arc sta~control

(consisting of)

Fl

....

*012 658

FUSE,

mintr

gi

sb-bID 2A

PLG1,6...

130203... CONNECTOR & SOCKETS

134 201

...

STAND-OFF

SUPPORT,

PC card .312/.375

GS1

155 404...

603 106...

010 865...

....

125 785...

605227...

147571

...

BRACKET, mtg components

HOSE,

nprn brd

No. 1

(order by ft)

CLAMP,

hose .430-.515

clp

dia

VALVE,

24VAC 2 way custom port 1/8 orf

NUT,

nylon

hex

jam

.75ONPST

HANDLE

12

SRi

155399...

605 077...

044426...

154848...

154 695

119 607

154 849

C4,R3...

156 237

151880

PANEL, rear

CABLE, port

No.

10 3/c

(460V Model) (order by ft)

CONNECTOR, clamp

cable .690/1.070

RECTIFIER, si diode

(consisting of)

RECTIFIER,

straight polarity (consisting of)

DIODE, rect 35A 1000V RP

BUS BAR, rectifier

CAPACITOR/RESISTOR

CAPACITOR

19...

FM

Zi

154 696

119 351

VR1,R2...

044482...

150783...

148 808...

155 403...

155469...

RECTIFIER, reverse

polarity (consisting of)

DIODE, rect 35A 1000V SP

SUPPRESSOR

BLADE, fan 9 in .312

hub

MOTOR, fan 230V 1550RPM .3l2dia

shaft

BRACKET,

mtg

fan & rectifier

STABILIZER

Ti

Ti

TP1,2

W

C2

Cl

161 389...

161 390...

176170

083 147...

034 260...

TRANSFORMER,

pwr main

380V

(consisting of)

TRANSFORMER,

pwr main 415V

(consisting of)

THERMOSTAT,NC

GROMMET,

screw

No. 8/10

panel

hole

.312sq

.500

LINK, connecting

contactor terminal

CONTACTOR

high

035519...

155 501

...

155 290...

CAPACITOR

CAPACITOR

T2

Z2

Si

155 107...

157 596...

155 499...

159 102

155 288

124 511

...

165987...

CABLE TIE,

push

mount 0-1.500

bundle

TRANSFORMER, impLilse

HV

TRANSFORMER,

PLATE,

blocking (consisting of) mtg

block transformer

COIL,

blocking

SWITCH, tgl

DPST 40A 600VAC

BASE

Elec

Ri

186 092...

035 897...

RECEPTACLE KIT, dinse

POTENTIOMETER, C sltd iT 2W 1K ohm

134 900...

STRAIN

RELIEF,

cable flex .270-.480

cable

...39....RC1....

143 976...

CONNECTOR w/SOCKETS

134 734...

134 731

...

079 739...

143 922...

097 924...

PL3....

155 500...

148 956...

PL2....

157 957...

CONNECTOR,

circ 14 pin

plug Amp

213571-2

CONNECTOR,

circ

pin push-in 14-l8ga Amp

213603-1

CONNECTOR,

circ damp str rlf sz

17-20

Amp

206322-2

(or)

CONNECTOR,

circ

clamp

str rlf sz

17-20

Amp

206070-3

KNOB, pointer

LIGHT,

indicator

HANDLE, switch

LIGHT, md blu lens 28V snap

mtg

OM-167 439

Quantity

1

2

4

2

1

1

I

1

1

1

1

1

1

2

1

1

1

1

1

2

1

8ft

1

1

1

1

1

1

1

6

1

6

1

1

2

1

4

3ft

2

I

1

2

4

1

1

I

1

1

1

1

1

1

23

9.1

Item

No.

47

(Continued)

Dia.

Mkgs.

Part

No.

Description

S3

PL1

S2

S4

....

155013...

157958...

155422...

154896...

089645...

SWITCH,

rocker SPST 1OA 25OVAC

NAMEPLATE,

(order by

model and serial

number)

LIGHT,

md wht lens 28V

PANEL, front

SWITCH, polarity (consisting of)

SWITCH, urn hA 125V roller lever actr

600317...

028594...

CABLE,

weld/cop

strd No.

4

(order by ft)

BODY, electrode holder

025475...

028593...

128188...

128434...

SPRING,

cprsn

.490

OD x

.090 wire

LEVER,

clamp

electrode holder

HOSE,

gas

REGULATOR/FLOWMETER

134460...

010368...

026843...

CONNECTOR,

twlk insul male

CLAMP, work 200A

INSULATOR,

vinyl

black

+When

ordering

a component

originally displaying

a

precautionary

label, the label should also be ordered.

* Recommended

To maintain the

Spare

Parts.

factory original performance

of your

equipment,

use

only

Manufacturers

Suggested

Replacement

Parts. Model and serial number

required

when

ordering parts

from your local distributor.

Quantity

1

1

1

1

1

1 l5ft

1

1

1

2

1

1

1

1

24

OM-167 439

Notes__

__

__

___

0141674%

25

Options

and Accessories

iig

6/98

~

Caster Kit

#042811

Allows Econotig to be moved short distances. Does

~ not include gas cylinder rack.

RHC-1 4 Hand Control #129 340

Miniature hand control for remote current and contactor control. Dimensions: 4 in (102 mm) x

4 in (102 mm) x

3-1/4 in (82 mm).

Includes

20 ft (6 m) cord and 14-pin plug.

Universal Carrying Cart and

Cylinder

Rack

#042 934

This cart adds convenience to the Econotig package.

The power source mounts securely to the top, and a cylinder rack supports the argon cylinder.

The bottom tray can hold electrode leads or welding hood, gloves, etc.

Cylinder rack will accommodate 6gin (152

228 mm) diameter, and 2456 in (6101422 mm) high cylinders.

Also supports five standard TIG filler metal tubes and one

Stick welding rod tube. Net shipping weight is 69 lbs

(31 kg).

RCC-14 Remote Contactor and

Current Control #151 086

Comes standard with 50Hz units.

A fingertip control can be used instead of the supplied remote foot control.

Useful when welding where a foot control cannot be used.

This rotary motion fingertip control fastens to

TIG torch handle using two Velcro strips.

Includes 28 ft (8.5 m) cord and plug.

Allows complete current and contactor control.

RFC-1 4 Foot Control #129339

Comes standard with 60Hz units.

Heavy duty foot current and contactor control.

Includes 20 ft (6 m) cord and 14-pin plug.

OM-303

Warranty

Questions?

Call

1 -800-4-A-MILLER for your local

Miller distributor.

f//A

w

Miller

The Power

ofBbi.

Effective January 1, 1997

(Equipment

with a serial number

preface

of RH or

newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with guarantees or warranties expressed or implied.

no other

LIMITED WARRANTY Subject to the temrs and conditions below, Miller Electric warrants to its

Mfg.

Co., Appleton, Wisconsin, original retail purchaser that new

Miller equipment sold after the effective date of this limited warranty is free of defects In material and worlmanship 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 componenis 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.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure wil:hin the warranty time periods.

All warranty time periods stan on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment Is sent to an International distributor.

Millers

1.

2.

3.

True Bluefi Limited Warranty shall not apply to:

Items furnished such as by Miller, but manufactured by others, engines or trade accessories.

These Items are covered by the manufacturers

Consumable components; such nozzles, contactors, brushes, slip that fail due to normal wear.

warranty, If as contact any.

tips, rings, relays cutting or parts

Equipment that has been modified

Industry standards, or by any party other than Miller, or equipment that has been installed,

Improperly improperly operated or misused based upon equipment which has not had reasonable and necessary which has been used for maintenance, or equipment operation outside of the specifications for the equipment.

MILLER PRODUCTS ARE

AND USE BY

INTENDED FOR PURCHASE

COMMERCIAL/INDUSTRIAL USERS AND

PERSONS TRAINED AND EXPERIENCED IN THE USE

AND MAINTENANCE OF WELDING EQUIPMENT.

1.

2.

3.

4.

5 Years Parts3 Years Labor

Original main power rectifiers

Inverters (input and output rectifier; only)

3 Years Parts and Labor

*

*

*

*

Transformer/Rectifier Power Sources

Plasma Arc Cutting Power Sources

Semi-Automatic and Automatic Wire Feeders

Inverter Power Supplies

Intellitig

Robots

Engine Driven Welding Generators

(NOTE: Engines are warranted separately by engine manufacturer.) the

1 YearParts and Labor

*

*

*

*

*

*

*

Motor Driven Guns

Process Controllers

Positioners and Controllers

Automatic Motion Devices

Orbital Weld Heads

IHPS Power Sources

Water Coolant Systems

HF Units

Grids

Spot Welders

Load Banks

SDX Transformers

Miller Cyclomatic Equipment

Running Gear/Trailers

Plasma Cutting Torches (except APT, ZIPCUT &

PLAZCUT Models)

Deutz Engines (outside North America)

Field Options

(NOTE: Field options are covered under True Bluefi forthe remaining warranty period of the product they are installed in, or for a minimum of one year whichever is greater.)

6 Months Batteries

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Millers option: (1) repair; or

(2) replacement;

TO THE EXTENT or, where authorized In

PERMIUED BY

ANY OTHER LEGAL THEORY.

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 customers risk and expense.

Millers option of repair or replacement will be F.O.B., Factory at Appleton,

Wisconsin, or

FOB. at a Miller authorized service facility as determined by Miller.

Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

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

AND

EXPRESS WARRANTY NOT PROVIDED HEREIN

ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO

REMEDY FOR BREACH OF

PERFORMANCE, AND ANY

CONTRACT TORT OR

ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION,

OPERATION OF

MIGHT ARISE BY IMPLICATION,

LAW, CUSTOM OF TRADE OR COURSE

OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR

PURPOSE, WITH RESPECT TO ANY

PARTICULAR

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 provides specific legal rights, and other available, but may vary from state to state.

rights warranty may be

5.

*

90 Days Parts and Labor

MIG Guns/TIG Torches

APT, ZIPCUT & PLAZCUT Model Plasma

Torches

Cutting

Remote Controls

Accessory Kits

Replacement Parts (No labor)

In Canada, legislation additional warranties

In some or provinces provides for certain 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.

milIer_warr 3/97

Owners Record

Please

complete

and retain with your

personal

records.

Serial/Style Number Model Name

Purchase Date

Distributor

Address

City

State

(Date which equipment was delivered to original customer.)

Zip

~

Resources Available

Always provide

Model Name and

Serial/Style

Number.

Contact your Distributor for:

To locate distributor nearest you call

1-800-4-A-Miller.

Contact the DeliverIng Carrier for:

For assistance in filing or settling claims, contact your distributor and/pr equipment manufacturersTransportation Department.

Welding Supplies

and Consumables

Options

and Accessories

Personal

Safety EquIpment

Service and

Repair

Replacement

Parts

Training (Schools, Videos, Books)

Owners Manuals

Technical Manuals

(Servicing

information and

Parts)

Circuit

Diagrams

Welding

Process Handbooks

File a claim for loss or

damage during ship

ment.

::.

.,::,::::~:~~

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~

~

~flSs~

~.

~ flt_ :;~

<~

\

.~

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...

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ta~s ~

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k

~ ~

~ nv~tt~ ttZS~~\ ;~ t~t~~rP$s~ ~.

~pwiz~

_~~-~

~

..~&

~ ~t~ms ~

~q

~

:~

~

~

~

~

~.

W5~\~fl.fl~t..

~

~

~

.~

~

.

11w1r9 ~k\ k~s~

~

~

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~

~

~

p*~

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~n

~Ich~

~

~p s~8r s

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,:_

~__ _::

~

~: __~~ ~

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r~:-~c~~

:~N~

T~ ::~:

N2

:

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~,

-:-t .

~

,,.

~~~?:N

~

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~ :~:~: N~ -~ :-:-~

~

~

~ ~::::::

:::-

-:

~

~

~.

~

::::.-:::i

:-

j~W4~.t-~L~

~N

NrN~~

~N:

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~ ~NV aat~:t

~flta~.\ te ~

~~(/~fl a~ flt;&~

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-:

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N:: :.:.

:~:

:::

:~::::-

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~:

~:

\1~ ~rn~

H.

:-::

W~

~ ~

~

~..

H::

:~H

I/I

--

.7

--:

'

1996 Miller Electric Mtg.

co.

PRINTED IN USA