Miller ECONOTIG Owner’s Manual

 Visit our website at
www. millerweids.com
7/4 Miller.
The Power of Blue.
0M-3036 155795
November 1997
Processes
4 Gas Tungsten Arc
(TIG) Welding
Shielded Metal Arc
a (Stick) Welding
Description
pA
Arc Welding Power Source
Econotig
Thank you and congratulations on choosing Miller. Now
you can get the job done and get 1t 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 1n 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, there's a
Troubleshooting section that will help you
Miller is the first welding | figure out what the problem 1s. The parts list
CON MA ACID , will then help you to decide which exact part
e U.$.A, to he registere |
to the (SO 9001 Quality YO! May need to fix the problem, Warranty and
System Standard. service information for your particular model
are also provided.
QUALITY SYSTEM
Miller Electric manufactures a full Jine
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.
Working as Marias you do —
every power source from
Killer is hacked By the most
hassie-free warranty In the
business. |
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor 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.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
For practical information on
welding, process applica-
tions, and Miller products,
visit our website at
Wwww.millerwekis.com
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
OM-303G
TABLE OF CONTENTS
EEE AE ee ООООАО НИЯ
SECTION 1 - SAFETY PRECAUTIONS........eercoecannrorosareamertanaatrvnrerénmannTa 1
1-1. Symbol Usage........220 004444 eee a a ea eee ee A4 A AA ea Area ee ee Ra A ea Se ea a a ee 100 1
1-2. Arc Welding Hazards........2000 00404444 ee ee ee ea A A A ae a A a RED 1°
1-3. Additional Symbols for Installation, Operation, and Maintenance . ................... 3
1-4. Principal Safety Standards . .... oa 3
1-5. EME INfOrmation . o.oo ee ee ea 4
SECTION 1 - CONSIGNES DE SECURITE........e—_—eerreeersonreacéraastrrean re rrmerenaa 5
1-1. Signification des symboles. .. rr rrenrrA RRA 5
1-2. Dangers relatifs au soudage à l'arc. .......0220020 00 a aa aa aa ee sa sea a a ee eee res» 5
1-3. Dangers supplémentaires en relation avec l'installation, le fonctionnement
et la maintenance.............. paa ea Y
1-4. Principales normes de sécurité ........ EP 8
1-5. information sur les champs électromagnétiques. . ........ co i iii ii 8
SECTION 2 - INTRODUCTION. .....e.e.ereesaeavor=rasnnaamoareesone0neann rem 9
2-1. Included with Your Unit... 112202004004 ee 9
2-2. Specifications .........202 000044 444 e 4 sa ae ee A a 4 Aa ee Ra Ar Eee ee Rae 0 9
2-3. Duty Cycle Chart ......10200 000 L eee eee ae eee eee eee ea a eee ee ae aa ee 9
2-4. Volt-Ampere Curves.......122014 44044044 aa 4 ae 4 aa ee te ea 10
SECTION 3 - INSTALLATION. 1.222210 0 sa 0 eu a serum ce eee aan a aa 0000 10000 S UNSS AUS 00 T0 10
3-1. Selecting a Location.........222002 0440004 a eee aa ae da ee ea a A ER AAA 10
3-2. Typical Stick Connections. ............ ee ee eee ea 10
3-3. Typical TIG Connections... oii ee 11
3-4, Electrical Service Guide. . .......... ee ee eae eee 12
3-5, Connecting Input Power, ............_.o ee: rre aa ae» 12
SECTION 4 - OPERATION .....e.erreere=a=nraarnanoarseoneaartacanumene rervrródtacaraZz. 13
4-1. Controls ....,......oe.eeerereecier er errerere renacer ra rreverecrr econ 13
4-2. Example of Front Panel Amperage Control...........e e. reerrrreeresrreeee 14
4-3. Example of Remote Amperage Control. ..............esem0eerrerrrerereni re r ee» 14
4-4. Process and Material Thickness Guide Label ,.............oeerrreeeeanire sm ADA 15
SECTION 5 - MAINTENANCE AND TROUBLESHOOTING. .........errmenvevevexonnenneo a 16
5-1. Routine Maintenance. ........._ o ee..r.írxreriri 000 eri KG 16
5-2, Troubleshooting .... cco. Aerea es 16
SECTION 6 - ELECTRICAL DIAGRAMS.......r—-—-——-—ecsnnornoovenarorecareaaarrenerne rear AE
SECTION 7 - HIGH FREQUENCY ........-2--- 00000 a mu uma use 0eme anus see mA AE EAN C0 E 055 18
7-1. Welding Processes Requiring High Frequency . ............cc. iii iii, 18
7-2. Incorrect Installation. ... ce Cea 18
7-3. Correct Installation . .... cco eee 000 19
8. PARTS LIST. .....eesernunvovevvonrenaaneranmenimenevvoxacacanntanuamerEt e vrewrr ao 20
OPTIONS AND ACCESSORIES
WARRANTY
SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
Means Warning! Watch Out! There are possible
hazards with this procedure! The possible hazards are
shown in the adjoining symbols,
ул
A Marks a special safety message.
[=F Means “Note”; not safety related.
A 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 1-4. 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.
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.
® Do not touch live electrical parts.
e Wear dry, hole-free insulating gloves and body protection.
e [Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground,
e Donotuse AC outputindampareas, ifmovementis confined, orif
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 28 CFR 1910.147 (see Safety Standards).
® Properly install and ground this equipment according to its
Owner's Manual and national, state, and local codes.
e 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.
e When making input connections, attach proper grounding
conductor first — double-check connections.
e Frequently inspect input power cord for damage or bare wiring —
replace cord immediately if damaged ~ bare wiring can kill.
e Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
>“
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
e 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.
e Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
e Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
e Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
e Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
® Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
e Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health. |
e Keep your head out of the fumes. Do not breathe the fumes.
e [f 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 (MSDSs) and the
manufacturer's instructions for metals, consumables, coatings,
cleaners, and degreasers.
e Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be 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.
Ф Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, untess 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.
OM-303 Page 1
Arc rays from the welding process produce intense
visible and invisible {ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fiy off from the
weld.
e Wearawelding helmetfitted 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.
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.
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.
e 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 F4.1 (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.
¢ Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
e Wear approved safety glasses with side
shields even under your welding helmet.
OM-303 Page 2
Shut off shielding gas supply when not in use.
® Always ventilate confined spaces or use
approved air-supplied respirator.
Do not touch hot parts bare handed.
e Allow cooling period before working on gun or
torch.
Pacemaker wearers keep away.
e Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
Noise from some processes or equipment can
damage hearing.
e Wear approved ear protection if noise level is
Shielding 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.
e Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
e 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.
e Keep protective cap in place over valve except when cylinderis in
use or connected for use,
e Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
e 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.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
e Use equipment of adequate capacity to lift and
support unit,
e [fusing lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
e Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
e Do not block or filter airflow to unit.
Put on grounded - wrist strap BEFORE
handling boards or parts.
e Use proper static-proof bags and boxes to
store, move, or ship PC boards.
e Keep away from moving parts.
e Keep away from pinch points such as drive
rolls.
e Donot press gun trigger until instructed to do
so.
e Donot point gun toward any part of the body,
other people, or any metal when threading
welding wire.
Safety in Welding a andard 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, MÁ 02269.
. Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
e 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.
e The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
e If notified by the FCC about interference, stop using the
equipment at once.
e Have the installation regutarly checked and maintained.
e 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.
e Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
e 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.
e Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
e Be sure this welding machine is installed and grounded
according to this manual.
e If interference still ccours, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, rom Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada MSW 1R3.
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 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MÁ 02269.
OM-303 Page 3
Conside
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: "The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-303 Page 4
Keep cables close
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4, Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as
possible,
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 - CONSIGNES DE SECURITE - LIRE AVANT
UTILISATION
som _nd_Fre 4/97
Signifie Mise en garde t Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Á
À ¡dentifie un message de sécurité particulier.
[7 Signifie NOTA ; n'est pas relatif à la sécurité.
[YW
Ce groupe de symboles signifie Mise en garde | Soyez vigilant! il y a des
risques de danger reliés aux CHOGS ELECTRIQUES, aux PIECES EN
MOUVEMENT etaux PIECES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prend re pour
éviter tout danger.
A Les symboles présentés ci-aprés sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité
énumérées à la section 1-5. Veuillez lire et respecter toutes ces
normes de sécurité.
L'installation, l’utilisation, l'entretien et les réparations ne doi-
vent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenirtoute personne à l’écart et plus par-
ticulièrement les enfants.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L'electrode et le circuit de soudage sont sous tension
dès que l'appareil est sur ON. Le circuit d'entrée et les
circuits internes de l'appareil sont également sous
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d'entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
e Ne jamais toucher les pièces électriques sous tension.
e Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
e S'isoler de la pièce et de la terre au moyen de tapis ou d'autres
moyens isolants suffisamment grands pour empêcher le contact phy-
sique éventuel avec la pièce ou la terre.
e Ne pas se servir de source électrique acourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
e Se servir d'une source électrique äcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d'une source électrique àcourant électrique s'avère nèces-
saire, se servir de la fonction de télécommande si l'appareil en est équipé.
# Couper l'alimentation ou arrêter le moteur avant de procéder à l'instal-
lation, à la réparation ou à l'entretien de l'appareil. Déverrouiller
l'alimentation selon la norme OSHA 29 GFR 1910.147 (voir normes
de sécurité).
# Installer et mettre àlaterre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
e Toujours vérifier la terre du cordon d'alimentation — Vérifier et s'assu-
rer 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
a une prise correctement mise a la terre.
e Eneffectuant les raccordements d'entrée fixer d’abord le conducteur
de mise á la terre approprié et contre-vérifier les connexions.
e Verifier frequemment le cordon d'alimentation pour voir si nest pas
endommagé ou dénudé - remplacer ie cordon immédiatement s'il est
endommagé — un câble dénudé peut provoquer une électrocution.
e Mettre l'appareil hors tension quand on ne l'utilise pas.
® Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
® Ne pas enrouler les câbles autour du corps.
e Silapièce soudée doit être mise à la terre, le faire directement avec un
câble distinct — ne pas utiliser le connecteur de pièce ou le câble de
retour.
e Ne pas toucher l'électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d'une autre machine.
e N'utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
e isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimenta-
tion électrique.
e Arrêter les convertisseurs, débrancher le courant électrique, et dé-
charger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.
3 soudage génère es g
4 x inhalation peut être dangereux pour votre santé.
e Eloigner votre tête des fumées, Ne pas respirer
les fumées.
e À l'intérieur, ventiler la zone et/ou utiliser un échappement au ni-
veau de l'arc pour l'évacuation des fumées et des gaz de soudage.
e Si la ventilation est insuffisante, utiliser un respirateur à alimenta-
tion d'air homologué.
Lireles spécifications de sécurité des matériaux (MSDSs) et les ins-
tructions du fabricant concernant les métaux, les consommables,
les revêtements, les nettoyants et les dégraisseurs.
e 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 dôment 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.
e 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.
e Ne pas souder des métaux munis d’un revêtement, tels que l'acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n'ait êté enlevé dans la zone de soudure, que l'endroit soit
bien ventilé, et si nécessaire, en portant un respirateur à alimenta-
tion d'air. Les revêtements et tous les métaux renfermant ces élé-
ments peuvent dégager des fumées toxiques en cas de soudage.
OM-303 Page 5
Le rayonnement de l'arc du procédé de soudage
génère des rayons visibles et invisibles intenses
{ultraviolets et infrarouges) susceptibles de provoquer
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées
pendant le soudage.
e Porterun casque de soudage muni d'un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regar-
der (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
e Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
e Utiliser des écrans ou des barrières pour protéger des tiers de l'éclair
et de l’éblouissement; demander aux autres personnes de ne pas re-
garder l'arc.
e Porter des vêtements de protection constitué dans une matière dura-
ble, résistant au feu (cuir ou laine) et une protection des pieds.
Le soudage effectué
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être
projetées de l’arc de soudure. La projection d’étincel-
les, 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,
verifier et s’assurer que l'endroit ne présente pas de danger.
e Se protéger et d’autres personnes de la projection d’étincelles et de
métal chaud.
e Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
e Déplacer toutes les substances inflammables à une distance de 10,7
m de l'arc de soudage. En cas d'impossibilité les recouvrir soigneuse-
ment avec des protections homologués. .
e Des étincelles et des matériaux chauds du soudage peuvent facile-
ment passer dans d'autres zones en traversant de petites fissures et
des ouvertures,
e Surveillertout déclenchement d'incendie ettenir un extincteur à proxi-
mité.
e Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
e Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu'ils n'aient été prépa-
rés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
e Brancher le câble sur la pièce le plus près possible de la zone de sou-
dage pour éviter le transport du courant sur une longue distance par
des chemins inconnus éventuels en provoquant des risques d’élec-
trocution et d'incendie,
e Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées,
e En cas de non utilisation, enlever la baguette d'électrode du porte-
électrode ou couper le fil à la pointe de contact.
e Porter des vêtements de protection dépourvus d'huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans re-
vers, des chaussures hautes et un couvre chef.
e Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
® Le soudage, l’écailement, le passage de la pièce
a la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volan-
tes. Pendant la période de refroidissement des soudures, elles risquent
de projeter du laitier.
e Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-303 Page 6
e Fermer l'alimentation du gaz protecteur en cas de
non utilisation.
e Veiller toujours à bien aérer les espaces confinés ou se servir d'un respi-
rateur d'adduction d'air homologué.
e Ne pas toucher des parties chaudes à mains
nues
e Prévoir une période de refroidissement avant
d'utiliser le pistolet ou la torche.
e Porteurs de stimulateur cardiaque, restez à distance.
e Les porteurs d'un stimulateur cardiaque doivent
d'abord consulter [eur médecin avant de s'approcher
des opérations de soudage à l'arc, de gougeage ou
de soudage par points.
Le bruit des processus et des équipements peut affecter
Гоше.
e Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
sous haute pression. Si une bouteille est endomma-
ée, elle peut exploser. Du fait que les bouteilles de gaz
ont normalement partie du procédé de soudage, les
manipuler avec précaution.
e Protéger les bouteilles de gaz comprimé d'une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, des étin-
celles et des arcs. ,
e Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
e Tenir les bouteilles éloignées des circuits de soudage ou autres cir-
cuits électriques.
e Ne jamais placer une torche de soudage sur une bouteille a gaz.
# Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
e Ne jamais souder une bouteille pressurisée — risque d’explosion.
e Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
e Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
e Maintenir le chapeau de protection sur la soupape, sauf en cas
d'utilisation ou de branchement de la bouteille.
e Lireetsuivre les instructions concernant les bouteilles de gaz com-
primé, les équipements associés et les publications P-1 CGA énu-
mérées dans les normes de sécurité.
e Ne pas placer l'appareil sur, au-dessus ou à
proximité de surfaces inflammables.
e Ne pas installer l’appareil à proximité de produits inflammables
e Ne pas surcharger installation électrique - s’assurer que l’alimen-
tation est correctement dimensionné et protégé avant de mettre
l'appareil en service.
e Utiliser l'anneau de levage uniquement pour sou-
lever Pappareil, NON PAS les chariot, les bouteil-
les de gaz ou tout autre accessoire.
e Utiliser un engín d’une capacité appropriée pour
| soulever l'appareil.
e Enutilisant des fourches de levage pour déplacer l'unité, s'assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l'appareil.
TN Fpeut
$ e Prévoir une période de refroidissement, respec-
e ter le cycle opératoire nominal.
eg Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
e Ne pas obstruer les passages d'air du poste.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
e Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer où expédier des cartes de
circuits imprimes,
e Ne pas s’approcher des organes mobiles,
e Ne pas s'approcher des points de coincement
tels que des rouleaux de commande.
® Ne pas appuyer sur la gachette avant d'en avoir
recu l'instruction.
® Ne pas diriger le pistolet vers soi, d'autres per-
sonnes ou toute pièce mécanique en engageant
ie fil de soudage.
e Rester à l'écart des organes mobiles comme le
ventilateur.
e Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection,
e Lerayonnement haute frequence peut provoquer
des interférences avec les équipements de ra-
dio-navigation et de communication, les services
de sécurité et les ordinateurs.
e Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l'installa-
tion.
e L'utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l'installation.
e Sile FCC signale des interférences, arrêter immédiatement l’appa-
reil,
e Effectuer régulierement le contróle et I'entretien de l'installation.
e 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 et un blindage pour réduire les inter-
férences éventuelles.
e 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.
e Veiller à ce que tout l‘équipement de la zone de soudage soit com-
patible électromagnétiquement.
e 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).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
e Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d'emploi.
# Encas 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.
e Porteurs de stimulateur cardiaque, restez à dis-
tance.
e Les porteurs d'un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s'appro-
cher des opérations de soudage à l'arc, de gou-
geage ou de soudage par points.
OM-303 Page 7
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, de ’American Welding Society, 550 N.W. Lejeune Rd, Mia-
mi FL 33126
National Electrical Code, NFPA Standard 70, de la National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA 02269.
Données sur le soudage électrique et sur les effets, pour Forganisme,
des champs magnétiques basse fréquence
L’extrait suivant esttiré des conclusions générales du document intitu-
lé Biological Effects of Power Frequency Electric & Magnetic Fields —
Background Paper, OTA-BP-E-53 (Washington DC : U.S. Govern-
ment Printing Office, mai 1989), publié par le Office of Technology
Assessment du Congrès américain : «… il existe maintenant d'abon-
dantes données scientifiques compilées à la suite d’expériences sur
la cellule ou d’études sur des animaux et des humains, qui montrent
clairement que les champs électromagnétiques basse fréquence peu-
vent avoir des effets sur l'organisme et même y produire des
transformations. Même s'il s'agit de travaux de très grande qualité, les
résultats sont complexes. Cette démarche scientifique ne nous per-
met pas d'établir un tableau d'ensemble cohérent. Pire encore, elle ne
nous permet pas de tirer des conclusions finales concernant les ris-
ques éventuels, ni d'offrir des conseils sur les mesures à prendre pour
réduire sinon éliminer les risques éventuels». (Traduction libre)
OM-303 Page 8
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, de la Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, nor-
me CSA W117,2, de l’Association canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada MOW
1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, norme ANSI 287.1, de lAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 515, de la National Fire
Protection Association, Batterymarch Park, Quincy, MÁ 02269.
Afin de réduire les champs électromagnétiques dans lenvironnement
de travail, respecter les consignes suivantes :
1 Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
2 Mettre tous les câbles du côté opposé de l’opérateur.
3 Ne pas courber pas et ne pas entourer pas les câbles autour de
vous.
4 Garder le poste de soudage et les câbles le plus loin possible
de vous.
5 Relier la pince de masse le plus pres possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les consignes mentionnées précédemment font partie de celles desti-
nées aux personnes ayant recours à un stimulateur cardiaque.
Veuillez consulter votre médecin pour obtenir plus de détails.
SECTION 2 - INTRODUCTION
2-1.
Included with Your Unit
1 Some assembly is required.
For options and accessories
see back of book or contact your
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-Connect (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
models)
“How-To” Videotape
RFC-14 Foot Control with
20 ft (6 M) Cord (60 Hz
models only. 50 Hz models
come with RCC-14
fingertip control instead.)
8 ft (2.4 m) Primary Cord
(Plug supplied with 230
Volt model only)
distributor.
2-2. Specifications
Max.
Rated Output at 20% Welding Amperage Range Open-Circuit Net
Duty Cycle ACHigh ACLow DC Voltage Rated Output KVA Dimensions Weight
TIG: 150 A at 15 VDC TIG Welding A Range 78 200 V-60 A (3.6)* | 12.0 H: 18 in (457 mm) 140 Ib
(GTAW) 150 A at 15 VAC 50-165 20-50 30-160 230V-52 A (3.0)* (0.64)* | Ww: 13in (330 mm) (64 kg)
Stick: 130A at 25 VDC Stick Welding A Range 78 460 V-33 A (1.5)* D: 251/, in (648 mm)
(SMAW) 150 A at 25 VAC 35-165 20-50 25-130 :
* {y While idling.
2-3. Duty Cycle Chart
WELDING AMPERES
30
% DU
40 50 60 70 BO 60100
TY CYCLE
GTAW:
150 À AC
2 Minutes
Welding
Duty cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
A Exceeding duty cycle can
damage
warranty.
20% Duty Cycle at 150 A AC/DC
SMAW: 20% Duty Cycle at 130 A DC, or
8 Minutes
Resting
unit and void
ST-157 648-A
OM-303 Page 9
2-4. Volt-Ampere Curves
AC VOLTS
Lo
5
DC VOLTS
0 1 1 Ё 1
0 50 100 150 200 250 300
AC AMPERES
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.
О 50 100 150 200 250 300
DC AMPERES
8861.1 10/91 — 51-157 625-В / 5Т-157 626-В
SECTION 3 — INSTALLATION
3-1. Selecting a Location
18 in
(460 mm)
18 in
(460 mm)
Position unit so air can circulate.
For information about sources of
high-frequency see Section 7.
For carts and caster kits see back
of book or contact your distributor.
ST-158 075
Par
1 Electrode Holder
2 Work Clamp |
Connect to receptacle as shown.
ST-157 858-A
OM-303 Page 10
3-3. Typical TIG Connections
5 1 Remote Control
ALS 2 Torch
Connect to receptacles as shown.
3 Work Clamp
4 Cylinder
Chain or secure cylinder to running
gear, wall, or other stationary
support.
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 ¢fh (cubic
feet per hour} (9.4 L/min).
Tools Needed:
I——€ 5/8, 1-1/8 in Ref. ST-157 858-A
OM-303 Page 11
3-4. Electrical Service Guide 5-0092J
[7 For 230 V models with wall receptacie, 100% duly cycle used to calculate data below. 20% duty cycle used for all other models.
Input Voltage 200 230 460
Input Amperes at Rated Output 59 52 33
Standard Fuse or Circuit Breaker Rating
(Max. Recommended) 30 Amps 80 Amps 40 Amps
Input Conductor Size (Min.) 10 AWG 6 AWG 14 AWG
Input Conductor Length (Max. Recommended) 42 ft (13 m) 135 ft (41 m) 85 ft (26 m)
Grounding Conductor Size (Min.) 10 AWG 8 AWG 14 ANG
Reference: 1996 National Electrical Code (NEC).
3-5. Connecting Input Power
| A Have only qualified persons
A > [ools Needed make this installation.
Е: В =
A Special installation may be
required where gasoline or
volatile liquids are present -
see NEC Article 511 or CEC
Section 20.
230 Volt Models:
Units come equipped with input
power cord and plug. Wall recep-
tacle is customer supplied. To
install, select type and size input
and grounding conductors using
Section 3-4. Conductor rating must
comply with national, state, and
local electrical codes.
GND/PE
7 —
Install and connect grounding con-
ductor and input conductors in
ой conduit or equivalent between wall
— | receptacle and deenergized line
7 \ disconnect device.
GND/PE
|.
Connect first. “ L2 All Other Models:
Г ——— Units come equipped with input
|
All Other
Models
power cord for installation into line
disconnect device. Select type and
size overcurrent protection using
230 Voit Section 3-4.
Models Only
GND/PE
230 VAC,
ST-161 454-A
OM-303 Page 12
SECTION 4 - OPERATION
4-1. Controls
Fa
sr
+
a
Br
ARC STARTER ACTIVE nv =
4 IN TIG MODE 0 a
A SIE >
DA
DO NOT SWITCH
UNDER LOAD
8
£0
STICK
RN © ne Ко.
OUTPUT ON
(CONTACTOR)
WELD PROCESS POWER
40 60
20
HIGH TEMP
SHUTDOWN
| ©
A 100%
AMPERAGE
> RATED OUTPUT
De ADO
STICK STICK TF9
VOLTS 25 = 15
AMPS 130 150 150
DUTY CYCLE 20% 20% 20%
MAX DCY 70 75 та
1 wWeld Process Switch
Use switch to select weld process.
In Stick position (down), weld output goes On
and Off with Power switch.
In GTAW (TG) 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
3 Power Switch
Use switch to turn unit, fan, and pilot light On
and Off.
4 Amperage Control
For Stick (SMAW), use control to adjust am-
perage within range selected by the Range/
Polarity Switch.
5 Stick (SMAW) Table
Use table to find approximate Stick amperage
output at Amperage control setting.
See Section 4-2 for example 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 4-3 for example of remote amper-
age control.
6 Range/Polarity Switch
Use switch to select range and polarity of weld
output.
Ref. ST-155 790-F
Current
(DCEN), use Electrode Negative position.
For Direct Electrode Negative
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 4-4 to find suggested type of weld
output for application.
7 High Temperature Shutdown Light
Lights when unit overheats and shuts down
(see Section 5-2),
8 Output On (Contactor) Light
Lights when output (contactor) and unit power
are on.
OM-303 Page 13
4-2. Example of Front Panel Amperage Control
— DC
AC TA APPROXIMATE OUTPUT
\,1850A — —
AY i Ny KA 40 60 a
ARC STARTER ACTIVE A a su
IN TIG MODE
A
L SN A,
® A | ) 20 80 50
DO NOT SWITCH | 79 43
UNDER LOAD 70 | 8 102 84
80 | 37 124 es
0 90 | as | 18 1
40 A 100%. to] 50 | +6 | 1%
STICK AMPERAGE In Example:
Range = DC
Percentage of Range = 50%
Select weld process. — Select range and polarity. — Select percentage. Weld Amperage Lea ADC
4-3. Example of Remote Amperage Control
== De
AC Ч
NJ 18-50A Sz ===
| y AN 60
ARC STARTER ACTIVE A a 40
IN TIG MODE
SDR
CA 20 80
DO NOT SWITCH
UNDER LOAD
«©
A 100%
STICK
AMPERAGE
Select weld process. — Select range and polarity. —— Select percentage. —
e A
GTAW Welding Amperage Range
or AC Low AC High DC
> 20-50 À 60-165 À 30-165 À
In Example:
Range = DCEN
Percentage of Range = 50%
Remote weld amperage = 30-98 A DC
Connect remote control. (50% of 30-165 A DC)
OM-303 Page 14
4-4. Process and Material Thickness Guide Label
Guideline For Welding Process And Output For Material
Material Thickness
Material And 22 да | 20 да 18 да | 16 да | 14 да 12 да | 11 ga 10 да 6 ga 2 ga -
Weld Output 0.033 in | 0.036 in | 0.048 in | 0.06 in | 0.07 in O.1in |0.125 in | 0.14in | 0.186 in | 0.25 in | 0.25+ in
0.8 mm | 0.2 mM | 1.2 mM | 1.5 mm | 1.8 mM | 2.55 mm | 3.2 mm : 3.6 mm | 4.8 mm | 6.3 mm t6.3+ mm
Steel Or Stainless Steel | SMAW
(=) у
A DCEN a "s
ELECTRODE GTAW With DCEP
NEGATIVE
Aluminum ." ".
N, Récommended
AC
OM-303 Page 15
SECTION 5 - MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
BP zu A Disconnect power before maintaining.
>“ IF Maintain more often during severe conditions.
:
WARN A >
Epi ju Clean and tighten weld terminals. A
Replace unreadable labels.
Repair or replace cracked gas
hose.
Repair or replace cracked weld
cable.
Replace o-ring in Electrode/Gas
Output receptacle if cracked.
6 Months
Blow out or vacuum inside.
5-2. Troubleshooting
Trouble Remedy
No weld output; fan does not run. Place line disconnect switch in On position (see Section 3-5).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-5).
Check for proper input power connections (see Section 3-5).
No weld output; fan on. Be sure Range/Polarity switch is not set between positions.
Tighten remote control connection to Remote 14 receptacle.
Check remote control (see remote control Owner's Manual).
Unit overheated. Allow unit to cool (see Section 2-3).
Fan not operating; weld output Check for and remove anything blocking fan movement.
available.
Have Factory Authorized Service Agent check fan motor.
OM-303 Page 16
SB-154 141-C
SECTION 6 - ELECTRICAL DIAGRAMS
с
| aT
27 IZ
| vo
—0_ 15 72
ое ма ad
re © o
da 99 я
| pr
MOT OY WE 5
O ——e _—
LE 18 М 97” ев| нотн ov [2S £2
HE
TT TT TT
ra OC |
- 1 79
Gal
O 3 g 76 |
idl |
| ® О;
13 NA 159 75 eS = y
g 3 >
és al ий А’ or 09 27 SP} +” AZ ar
ААА ЛА АЛЛА ААА ЛА Л
TT 8 109$ PT OS TU y o. =
FM Ai = ab HD D ч2 xD HD = = — -— I
Lu 582888 = € 8 E RER g 8 2e ©
A> + 27 << 1-0138
Ce
< 21-928
a> он ‘se
7 95”, 69 1d/628
3 >———][e 1-19 451/7983
a> = 1-10 5 1/28
> a on 191/1284
„” =
128 ES Ha
OM-303 Page 17
Figure 6-1. Circuit Diagram
SECTION 7 - HIGH FREQUENCY
7-1. Welding Processes Requiring High Frequency
1 High-Frequency Voltage
Helps arc jump air gap between
torch and workpiece and/or
stabilize the arc.
high freq1 11/96 - 5-0693
7-2. incorrect Installation
N 14
\
>
5-0694
Sources of Direct High-Frequency Sources of Conduction of High Sources of Reradiation of High
Radiation Frequency Frequency
1 High-Frequency Source (welding 7 Input Power Cable 10 Ungrounded Metal Objects
power le IF with buiit-in HF or 8 Line Disconnect Device 11 Lighting
separate HF uni te i.
5 Wa d Cables ) 9 Input Supply Wiring 12 Wiring | |
3 Torch 13 Water Pipes and Fixtures |
4 Work Clamp 14 External Phone and Power Lines
5 Workpiece
6 Work Table
OM-303 Page 18
7-3. Correct installation
Ground all
x Nonmetal
NN
=>
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
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.
metal
objects and all wi-
ring in welding zone
using #12 AWG
e.
Ground
workpiece
if required
by codes.
5 Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections .
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
6 Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7 External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 M) away from power and phone lines.
8 Grounding Rod
Consult the National Electrical Code for
specifications.
Ref. 5-0695 7 Ref. S-0695
Metal Building Requirements
9 Metal Building Panei 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 morethan 1/4
in {6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
OM-303 Page 19
SECTION 8 - PARTS LIST
[7 Hardware is common and
not available unless listed.
ST-801 399-B
Figure 8-1.Main Assembly
OM-303 Page 20
Dia. Part
No. Mkgs. No. Description Quantity
Figure 8-1. Main Assembly
e O 154 335... BEZEL, front ....... Nrenavana denia vandrroreaveneanrenrecrrerernevza 1
Quadra 176 254... LABEL, warning general precautionary ............ cco. 1
E кееккккккк.. +165 986 ... WRAPPER, ............00000r0rrerereereaareodrre rece era SA 1
4 ..... PC1 ....165 872... CIRCUIT CARD, arc start/control (consistingof) ..................... 1
Cee F1....*012658.....FUSE, mintr gl sio-blo 24 ............. coc iii 1
O PLG1,6 ... 130 203... CONNECTOR & SOCKETS ......22114 144 ee ee a a ee rene re 2
OB nara. 134 201... STAND-OFF SUPPORT, PC card .312/.375 ..... iii iii 4
‚ 6 .............. 155 404... BRACKET, mtg components ............ee_mrexvreererveereereere 1
nani 603 106 ... HOSE, nprn brd No. 1 (order by ft) ...... A RAS ЗИ
C8 O 010865... CLAMP, hose .430-.515 cip dia ........... cc iii TADA 2
9.... GST . 125 785... VALVE, 24VAC 2 way custom port 1/8 orf ...............--..es=esae... 1
AO nena. 605 227 ... NUT, nylon hex jam .750NPST ........... co iii ea 1
| eau 0 147 571... HANDLE ...........00rre0ereererere0ercnereeverervarenecanvoredcnz 2
C12 155 399... PANEL, rear ......... ee a a aa ee ae a ea 1
‚18 .............. 071 906 ..: CORD SET, 8-10ga 3/c (200V model) ........... iii. 1
13... PLG12 ...047 721... CORD SET, 250V 6-50P 8-10ga 3/c (230V model) ................... 1
Ec E 605 077 ... CABLE, port No. 10 3/c (460V Model) (order by ft) ................... Bit
C14 044 426 ... CONNECTOR, clamp cable .690/1.070 ............. coo. 1
15..... SR1 . 154 848 .. . RECTIFIER, si diode (consisting of) ............... co iii, 1
SC 154 695 ..... RECTIFIER, straight polarity (consisting of) .............—re..e._.—.—... 1
RAA 119607 ...... DIODE, rect 35A 1000V RP ..............000000m ere: 6
ATA 154 849 ..... BUS BAR, rectifier ..........eocoreoeocdoonverere errar A Erre 2
een C4, R3 ... 156237 .....CAPACITOR/RESISTOR ............ 3
eee 151 880 ..... CAPACITOR .... i i i iirc. 4
‚18 ............., 154 696 ..... RECTIFIER, reverse polarity (consisting of) ............._eorreeve. 1
RAS 119351 ...... DIODE, rect 35A 1000V SP .........esxecvrecvvrrereree ree: 6
19... VR1,R2... 044 482 .., SUPPRESSOR ............0020a0rererer o earoreenarar erecarar e 1
‚20 .............. 150 783... BLADE, fan 9 in .312 hub ........._o.e.e00emearerrrerenarrr rear 0. 1
21... FM..... 148 808... MOTOR, fan 230V 1550RPM .312diashaft ....................... ... 1
‚ 22 .............. 155 403 ... BRACKET, migfan &rectifier ............ ccc iii iit, 1
23... Zi... 155 469... STABILIZER ........eeeonmecacorearadeer a erre eeare rear »nrecaver. 1
‚ 24.,... T1..... 161 344 .. . TRANSFORMER, pwr main 200V (consistingof) ..................... 1
‚ 24..... LN 155 760... TRANSFORMER, pwr main 230V (consisting of) .............eme.e... 1
‚ 24 ..... T1..... 161 345 ... TRANSFORMER, pwr main 460V (consistingof) ..................... 1
Cee TP1,2 ...176170..... THERMOSTAT, NC ....... 2
e 2D ie 083 147 ... GROMMET, screw No. 8/10 panel! hole .312sq .500 high .............. 4
26...... W..... 188 009... CONTACTOR i i i i ie at eect aes 1
27. С2..... 155 501... CAPACITOR .... ooo ieee PS 1
28..... С1..... 155 290... CAPACITOR oii RK KK KK ron een 1
29 ..... T2 nu... 188 061 ... TRANSFORMER, impulse HV... RR 1
‚ 30..... Z2 ..... 155 499 ... TRANSFORMER, blocking (consistingof) .....................c.o.0, 1
E: O 159102 ..... PLATE, mig block transformer ............. coc iii. 1
1 BOL Las aa asc» 165288 ..... COIL, blocking ............._.—._eeereorrorerarier eee 1
„„33..... St..... 124 511... SWITCH, tgl DPST40A600VAC .......... oii 06 1
BA naa 165 987... BASE ee ea 1
35..... Elec .... 186092... RECEPTACLEKIT, dinse ......cci iii eee eee etnias 1
‚ 36..... Ri..... 035 897 ... POTENTIOMETER, C sitd 1T 2W 1Kohm ............... coins. 1
‚ЭТ кекекекккк.... 134 900 ... STRAIN RELIEF, cable flex .270-.480 cable ......................... 1
.38.... RC .143 976 ... CONNECTOR w/SOCKETS L.....202 0444 4 ea ea eee eee re aa es sa ere e 0 1
‚ 39 .............. 097 924 ... KNOB, pointer ..........201040 04440 aa eee aa aa a ee eee ea ee aa eas 1
.40..... PL3 ‚ 155 500 .. . LIGHT, Indicator ii ee a ee a ee a a ee 1
2. 41 .............. 148 956 ... HANDLE, sWilCh .... oo ie eens 1
42 ..... PL2 157 957... LIGHT, indblulens28Vsnap mtg ........ coo... 1
‚.. 43 ..... ss... 155 013 ... SWITCH, rocker SPST 10A 250VAC 11... 2022004604 4e sea eee ea 22 1
RE LS Larsen» NAMEPLATE, (order by model and serial number} ................... 1
OM-303 Page 21
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 8-1. Main Assembly
..45.....PL1 .... 157958... LIGHT, ind wht lens 28Y .................26.90800e0é00 ce 1
| .............. 155 422... PANEL, front ........... eaaaddac one neraanrdrerrorvvcrvrerrrarernvzv 1
7 ..... 52 ..... 154 896 ... SWITCH, polarity {consistingof) .............. ci ii i. 1
‚., 48..... 54 ...,. 089 645 ..... SWITCH, lim 11ÂÀ 125V roller lever actr ......... .... 200200000000 1
AB 600 317 .. . CABLE, weld/cop strd No. 4 (order by ft) ...........eo._...e.exeeerna 15ft
e BO anna 010368... CLAMP, work 200A ..........__eeeeeeeenoaecdrr reno» aeeavrre re. 1
Bl aaa 026 843 .. . INSULATOR, vinyl black .............0.00000r00íerererearere A 2
Ce er eee KIT, accessory (consisting of) ......... coon À
Cee 128188 ..... HOSE, gas ................. FT PIPPI 1
ARR AAA AS 128 434 ..... REGULATOR/FLOWMETER .......... cine 1
eee 176 840 ..... ELECTRODE HOLDER/CABLE, (consistingof) .................... 1
Cee ea 025475 ...... SPRING, cprsn 490 0D x .090wire .............. coven À
Ce eee 028594 ...... BODY, electrode holder .......... coi 1
Cee 028593 ...... LEVER, clamp electrode holder .............. o.oo 1
Cea 134460 ...... CONNECTOR, twikinsuimale ............ cocoon À
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-303 Page 22
OPTIONS AND ACCESSORIES
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 6 - 9 in.
(152 — 228 mm} diameter, and 24
— 56 in. (610 - 1422 mm) high
cylinders. Also supports five
standard TIG filler metal tubes and
one Stick welding rod tube. Net
shipping weight is 69 Ibs. (31 kg).
CASTER KIT
(#042 811)
Allows Econotig to be moved short |
distances. Does not include gas
cylinder rack.
RCC-14 REMOTE CONTACTOR
AND CURRENT CONTROL
(4151 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 b
used. О,
This rotary motion fingertip contro
fastens to TIG torch handle using
two Velcro strips. Includes 28 ft.
(8.5 m) cord and plug. Allows
complete current and contactor
control.
RHC-14 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.
RFCS-14 FOOT CONTROL
(#043 554)
Comes standard with 60 Hz units.
Foot current and contactor control.
Includes 20 ft.
(6 m) cord and 14-pin plug.
9/95
Warranty Questions?
Gall Ш
1-800-4-A-MILLER
for your local
Milier distributor.
| Miller
> The Power of Blue.
Effective January 1, 1997
(Equipment with a serial number preface of "KH" 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.
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 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.
1. 5 Years Parts — 3 Years Labor
Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 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 the
engine manufacturer.)
3. 1 Year — Parts and Labor
* Motor Driven Guns (w/exception of Spoolmate 185)
* 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 Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
4. 6 Months — Batteries
5. 90 Days — Parts and Labor
* MIG Guns/TIG Torches
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate 185
Miller's True Blue® Limited Warranty shall not apply to:
1. 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.
2. Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
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.
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 Appieton,
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 5/97
Owner's Record
Please complete and retain with your personal records.
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
[= 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.
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training {Schools, Videos, Books)
Owner's Manuals
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturers Transportation Department.
File a claim for loss or damage during
shipment.
PRINTED IN USA
O 1997 Miller Etectric Mig. Co. 8/97
Miller Electric Mig. Co.
An lIlinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters-USA
Phone: 920-734-9821
USA & Canaca FAX: 920-735-4134
intemational FAX: 920-735-4125
European Headquarters —
United Kingdom .
Phone: 44 (0) 1625-525556
‘FAX: 44 (0) 1625-537553
Miller.
The Power of Blue,