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OM107 439F April Eff. w/Se rial Number KH374223 Miller The Power ofBlue. Processes ~ ~ Gas Tungsten (TIG) Welding Arc Shielded Metal Arc (Stick) Welding Description Arc Welding Power Source CE 0 - lull I Visit our website at www.millerweids.com ! MANUAL 1997 ~ ~ ~ ~ - S~n~ ~ %~< ~ ~4W~$~ From Miller ito You ~k~%tt\~ \\~ ~ flfl~~ ~ ~ *~ ~ %%% ~ fl~&~, ?*~nfttt S$~J ~*~ ~ Thank you and can have time to do it any other way. you dont Thats ~~ Miller help Manual is products. you protect designed to help f~ A~ yourself against potential on r4~~j~k~ will the worksite. Weve operation quick k~*t~ REGISTERED QUALITY SYSTEM ~ Miller Is the first welding equipment manufacturer in the U.S.A. to be registered to the iSO 9001 Quaiity System Standard. ~N *~ 4H~N~~ -~-r and easy. ~ \~? ~~ :~ ~ ~ ::11:~::.~ ~ :::~ : ::1;~: ~ : ~ \~ N ~twc ~ N ~1pn~ -~aa~ t~:~ :~ ~S~net ~ ~ _ -~ N ~ea ~flWWWY~-*. I Miller Electric manufactures of welders and welding For information on a ~Sb~ full line s~ equipment. quality Miller your local Miller distributor to receive the latest full line catalog or products, ~a-~ I related other contact sheets. To locate your distributor call 1-800-4-A-Miller. individual catalog nearest :~:~:::1~~ ~ m$z~sa~ ta~ on ~ ~ 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 are also provided. count ~ ~ ~ ~SSI4~!~n can N % years of reliable service with proper maintenance. And if for some reason the unit needs repair, theres a With Miller you ______________ ~ a~ p!!t~!r~ ~ litlilil t ~ ~%N~ ~ made installation and ~ j~:: ~ ~t~Tra_N~ Safety precautions. They hazards t7t i~* you get the most out of your Please take time to read the N N~ ~aa the This Owners ~k - people that build and sell Miller producl:s continue the tradition. Theyre just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. Today, a ~ ~J 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 couldnt afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. why ~ ~ you congratulations on choosing Miller. Now get the job done and get it done right. We know N~ ~ - ~ -~ it/pr )NN Description 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 ranges, DC electrode ()forTlG, and DC electrode (+)for Stick Patented technologyand Millers vast experience in powersourcedesign cometogetherin atrulyafford 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. able and effective TIG The tive Patented, built-in TIG Process switch for TIG or Stick easy to use. Its an excellent choicefori,ovice users and hobbyists, but dont underestimate this arc assist stabilizer for AC arc assist starter for DC TIG aluminum Patented, built-in Econotigs unique design and Millers innova engineering make a system that is incredibly automatically sets machine Unique flow-through shielding gas TIG torch connection allows removal of torch without machines power. It has the strength arid stamina to handle a wide variety of light indus~riaI welding tasks. Yet it operates off single-phase power. 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. on tools Preset automatic postflow timer protects tungsten tip, workpiece and torch The Automatic Call tive welder. shutdown Processes Gas Tungsten (TIG) Welding IntheTIG mode, the Econotigofferssuperiorperfor mance: 18 gaugeto3/1 6in (1 .2to4.8 rnm)steel and stainless steel; 14 gauge to 3/16 in (1.3 to 4.8 mm) aluminum (see Section 5.4). For thicker 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 high temperature Arc Shielded Metal Arc ~ (Stick) Welding The following terms are throughout this manual: used interchangeably TIG GTAW Stick SMAW = = 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 inyourhands in 24 hours. Support Need fast answers to the Table of Contents Section 1. Safety Page Precautions 1 2. Definitions 9 tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. 3. Introduction 11 4. Installation 12 5. .~ Operation 5 Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, 6. Maintenance and Troubleshooting 18 contact your local distrib utor. Your distributor supply you 7. Electrical 8. Diagram High Frequency 19 20 with can Welding also Process Manuals such as SMAW, GMAW, and GMAW-P For practical information GTAW, on ing, 9. Parts List 22 www.mlflerwelds.com Options and Warranty Accessories weld process applications, and Miller products, visit our website at Declaration of Manufacturers Name: Miller Electric Manufacturers Address: 1635 W. Declares that the Conformity Mfg. Co. Spencer Street Appleton, WI 54914 USA E CO N OT I (~ ~ product: (product name) conforms to the following Directives and Standards: Directives Electromagnetic Compatibility Low Voltage Directives: 89/336EEC, 92/31/EEC 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 EN5O 199: Safety Requirements Arc forArc August arc welding equipment: 1995 Welding Equipment part 1: EN 60974-1: 1990 Welding Equipment Part 1: Welding Power Sources: (Apr11 1995 Draft revision) Degrees of Protection provided by Enclosures (IP code): IEC 974-1 IEC 529:1989 Insulation coordination for equipment within low-voltage systems: Part 1: Principles, requirements and tests: IEC 664-1:1992 European Contact: Mr. Luigi Vacchini, Managing Europe S.P.A. MILLER Via Privata lseo 20098 San Giuliano Milanese, Italy Telephone: Fax: dec_con 1 7/95 39(02)98290-1 39(02)98281-552 Director 1. Safety Precautions 11 Read Before Using Symbol Usage ~ ~ ......~...... .~ . ~. ~ ..~ ..~ :::~:.~ OM-167 439F Marks This group of symbols means Waming! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. special safety message. a ~ Means Note~ not safety related. ~E. ~ A The symbols : :.:.: .:. ::.. are used throughout this manual identify possible hazards. When you shown below to call attention to and symbol, watch out, and follow the related instructions 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. see the Only qualified persons repair A should install, operate, maintain, and this unit. : Do not drape If earth grounding with a to avoid the hazard. The A Date, safety_som 4/97 Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. a A - cables your body. workpiece is required, ground it directly do not use work clamp or work cable. over of the separate cable Do not touch electrode if you are in contact with the work, or another electrode from a different machine. Use ground, only well-maintained equipment. Repair or replace damaged at once. Maintain unit according to manual. parts Wear During operation, keep everybody, especially children, away. a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good or r~:SHOQKcawkIIL1..2~ ~ . worktable Insulate work . ~, as near metal-to-metal contact to the weld as workpiece practical. clamp when not connected to workpiece to prevent object. contact with any metal 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. Touching Do not touch live electrical 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. parts. ~ - Wear hole-free dry, Insulate insulating gloves and body protection. yourself from work and ground using dry insulating mats big enough to prevent any physical contact with the ground. or covers work or Do not use there is a Use AC If AC AC output in damp areas, if movement is confined, of falling. or output output is required, remote If output control if present fumes and gases. Breathing these fumes and gases can be hazardous to your health. on inside, remove out of the fumes. Do not breathe the fumes. ventilate the welding area and/or use exhaust at the If ventilation is poor, 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). Read manufacturers instructions for metals, consumables, cleaners, and degreasers. Properly install and ground this equipment according Work in Disconnect to its 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 Do not worn, use OM-167 439 when not in use. damaged, undersized, or poorly spliced cables. the arc to fumes and gases. unit. Owners 1 be hazardous Welding produces =9, Keep your head required for the welding process. use can if danger ONLY if FUMES AND GASES Material use an Safety approved air-supplied respirator. Data Sheets (MSDS5) and the coatings, a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. 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 cadmium on coated 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 can bum eyes and skin Shutoff shielding gas supply when not in Always ventilate confined spaces or approved air-supplied respirator. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can bum eyes and skin. Sparks fly off from the weld. use. use 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 .HOTPARTS can:: au~ under your helmet. Do not touch hot Use Allow protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear parts bare handed. before cooling period working on or gun torch. protective clothing made from durable, flame-resistant (leather and wool) and foot protection. material MAGNETIC FIELDS can affect VELDING can cause fire or explosion Pacemaker closed containers, such as tanks, 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 objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Protect Welding on drums, pipes, yourself or and others from Do not weld where flying sparks flying sparks Remove all flammables within 35 ft this is not possible, tightly cover going near arc welding, gouging, welding operations. ___________ fire, and Be that welding aware can cause fire Do not weld on on keep a fire (10.7 m) of the welding arc. approved covers. Noise from closed containers such Connect work cable to the work unknown Do not prevent welding paths use as and as tip tanks, drums, Wear can approved ear protection if noise level is high. CYLiNDERScanex~Iodefda~e~J causing 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. pipes, (see welding area as traveling long, possibly electric shock and fire hazards. welder to thaw frozen when not in or to AWS F4.i Protect or cut off welding wire at compressed gas cylinders from excessive heat, slag, open flames, sparks, and arcs. mechanical shocks, Install pipes. cylinders in an upright position by securing to a stationary or cylinder rack to prevent falling or tipping. support Keep cylinders away from any welding or other electrical circuits. use. protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Never Remove any combustibles, such Never weld Wear oil-free from your person before as a butane lighter or matches, doing any welding. FLY~NGMETM~fl!fljurغ~~ drape Never allow a a welding welding on a torch over a gas Wear shields approved safety glasses with side even under your welding helmet. cylinder. electrode to touch any pressurized cylinder Use cylinder. explosion will result. only correct shielding gas cylinders, regulators, hoses, fittings designed for the specific application; maintain them associated parts in good condition. Turn face away from valve outlet when Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. 2 equipment close to the current from Remove stick electrode from holder contact or the hidden side. they are properly prepared according Safety Standards). to processes If partition or some damage hearing. extinguisher nearby. unless practical spot NOISEcan~maeh~~ them with ceiling, floor, bulkhead, on a or and hot metal. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for keep away. wearers Wearers should consult their doctor before strike flammable material. can pac~makers~ and and opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions associated equipment, compressed gas cylinders, publication P-i listed in Safety on and CGA Standards. OM-i67 439 Syi~o1ifcr-$nstÆHation;.Op~ritIon,and~ MinienancŁ~. 1~~dditiq~aI ~--~ j )VtNG.~-PARTScancatiŁeinjr~. ~- - ---- Do not install place or unit on, over, Keep away from moving parts such or near combustible surfaces. Do not install unit near all doors, panels, covers, and closed and securely in place. flammables. fans. as Keep guards Do not overload building wiring be sure power supply system is properly sized, rated, and protected to handle this unit. PALUNG UNIT can cause injury -HFRADiOF~Ænc~se1nterte$nce.I Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacityto lift and High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and support unit. communications If Have equipment. only qualified persons familiar with electronic equipment perform this installation. using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. The is user responsible for having a qualified electrician problem resulting from the correct any interference installation. promptly OVERUSE can Allow cause OVERHEATING cooling period; follow rated duty cycle. Reduce current starting to weld Do not block or reduce or duty cycle before S Put S boards Use proper store, move, or wrist strap the FCC about Have the installation Keep high-frequency panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. regularly source ~-~~ such Injury robots. as all equipment in the welding electromagnetically compatible. such as sure is possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate can cause area To reduce drive tronic Injury Be welding operation equipment. sure according trigger Interference Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment rolls. Do not press gun can cause boxes to Keep away from moving parts. Keep away from pinch points ~ -~:r~-~ ~ Be WELDING WIRE checked and maintained. doors and BEFORE parts. can cause interference, stop using the boards static-proof bags and or ship PC boards. PARTS at once. S filter airflow to unit. grounded on handling by S again. (ESD) can damage PC If notified equipment until instructed to do this welding 100 meters from any sensitive elec machine is installed and grounded to this manual. If interference still occurs, the user must take extra measures as moving the welding machine, using shielded cables, so. such Do not point gun toward any part of the body, people, or any metal when threading welding wire. using line filters, or shielding the work area. other 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. OM-i67 439 ~ ~- Safe Handling of Compressed 1 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. 3 k EMF 5 Infrmat~on \ ~ Considerations About Welding And Electric And Fields Magnetic . The Effects Of Low ~ Frequency . To .:~. reduce ~ magnetic fields in the I ~ workplace, use the following procedures: 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 1. Keep cables close 2. Arrange cables 3 Do not coil together by twisting or taping them. to one side and away from the operator. OTA-BP-E-53 Paper, (Washington, DC: U.S. Government Printing there is now a very large volume of scientific Office, May 1989):.. 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 or drape cables around the bod . 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 strategies 4 of possible to minimize risk or or to offer clear science-based advice avoid potential risks. on 4. Keep welding power practical. source Connect work to and cables as far away from opera- tor as 5. clamp workpiece as close to the weld as possible. About Pacemakers: The above procedures are also recommended for Consult your doctor for complete information. pacemaker wearers. OM-167 439 . 1. Consignes do sØcuritØ ~ y;:~~ Signification ~1 1 .~ r???.~q~~ ~ symboles Signifie Mise en garde! Soyez vigilant! Cette procedure presente des risques de danger! Ceux-ci sont identifis a A des lire avant utilisation par des Identifie un symboles adjacents message de sØcuritØ aux directives. Ce groupe de symboles signifie Mise en garde I Soyez vigilant lily a des risques do danger relies aux CHOCS ELECTRIQUES, aux PIECES EN particulier. MOUVEMENT etaux PIECES CHAUDES. Reportez-vous aux symboles et aux directives ci-dossous af in de connaltre los mesures a lI~ Signifie nest pas relatif Dangers relatifs 1 2 A NOTA Øviter tout Ia sØcuritO. au soudage a Iarc 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 Nutiliser quun materiel en bon Øtat. ROparor ou romplacer sur-le champ les piŁces endommagees. Entretenir lappareil conformŁment ~ ce manuel. Porter que rØsumer linformation contenue dana lea normes de sØcuritØ ØnumØrØes a Ia section 1-5. Veuillez lire et respecter toutes ces normes do sØcuritØ. un hamais do sOcuritØ quand Maintenir solidement place en Fixer le cable do retour de A Linstallation, lutilisation, lentretien et lea reparations qua des personnes qualifiees. no doi avec vent ºtre confiØs A prendre pour danger. Au cours do lutilisation, tenir touts personne Ł lØcart et ticuliŁrement lea enfants. Ia piŁce a souder ou on travaille en hauteur. tous les panneaux et tacon a obtenir un capots. bon contact mØtal-mOtal Ia table de travail, le plus prŁs possible do Ia soudure. plus par Ranger et isoler correctoment Ia pince de masse aprŁs utilisation pour avec des objets relies a Ia masse. Øviter le contact UN CHOC Un simple ELECTRIQUE petit tuer~ 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 soudage semi-automatique ou automatiquo, le fit, Is dØvidoir, le 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 Ily DU COU RANT CONTINU IMPORTANT dans les a convertisseurs tion aprŁs Ia suppression de Ialimenta electrique. ArrOtor los convertisseurs, dØbrancher le courant charger les condensateurs dalimentation indiquees dans Ia partie entretien avant do eloctrique, selon los toucher les et de instructions piŁces. piŁces electnques sous tension. protection secs ne comportant Porter des gants et des vŒtements do pas de trous. 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. Se servir dune source electrique courant procØde de soudage le demande. ___.__I._I I 1t~ zones electnque UNIQUEMENT Si Le~ le J =9 Eloigner _____________ 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. DØverrouiller lalimentation selon Ia norme OSHA 29 CFR 1910.147 (voir normes de sØcuritØ). Installeret mettre ala terre correctement cet apparoil conformOment a et aux codes nationaux, provinciaux et son manuel dutilisation municipaux. Verifier et sassu Toujours verifier Ia terre du cordon dalimentation rer que le fil de terre du cordon dalimentation est bien raccordØ a Ia borne do terre du sectionneurou que Ia fiche du cordon est raccordØe a une pnse correctement 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 uses, endommages, do grosseur insuffi sante ou mal Opisss. Ne pas enrouler los cables autour du corps. 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 Si (a desL.............. inhalation pout Otre dangoroux pour v.... ~. votre tŒte des fumŁes. No pas rospirer los fumØes. A lintØneur, ventiler Ia veau zone de Iarc pour lØvacuation etlou utiliser un echappement au ni des fumØes ot des gaz do soudage. Si Ia ventilation est insuffisante, utiliser tion dair homologue. un respirateur a alimenta Lire los specifications do sØcuritØ des matØriaux (MSDSs) et los ins tructions du fabricant concernant los mØtaux, los consommables, los revØtements, les nettoyants ot los degraissours. Travaillor dans espace fermØ seulement siI est bien ventilØ ou 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. en portant un un rospirateur a alimentation Ne pas souderdans des endroits situØs ~ proximite dopOrations do do nottoyage ou do pulvØrisation. La chaleur et los rayons do larc peuvent reagir en presence do vapours ot former degraissage, des gaz hautoment toxiques et irritants. 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. retour. Ne pas toucher lØlectrode quand on est en contact avec Ia terre ou une electrode provenant dune autre machine. OM-167 439 piŁce, Ia 5 voquer des brOlures clans les yeux et surIapeau~ do soudago Le rayonnoment de larc du procdØ gØnŁro dos rayons visiblos et invisiblos intenses (ultraviolets ot infrarougos) suscoptiblos do provoquor des brluros pendant le dana los youx et sur Ia peau. Des Øtincelles sont projetØes soudage. C~J Former lalimentatlon utilisation. du gaz protecteur en cas de non Veillertoujours a blon aØrorles espaces confines ou rateur dadduction dalr homologue. 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 I trop ØlevØ. DES Se servir dun respl PIEqES~CHAUDE$peuvent pro voquerdes ~ j _______ Utiliser des Øcrans ou des barriŁres pour protØger des tiers do Øclair et do leblouissement; demander aux autres personnes done pas re garder larc. No pas toucher dos Porter des vØtements do protection constituØ dans une matiOro dura au feu (cuir ou lame) et une protection des pieds. LE chaudos a mains PrØvoir une pØriodo do refroidissoment avant dutiliser le pistolet ou Ia torche. ble, resistant ~ parties nues SOUDAGE~~tut provoquerun: une expIoslon~ incendleou peUvent sUmulateurs cardiaques 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 chaudes et des equipemonts chauds pout provoquer des los, dos piŁces incondies ot des brOlures. Le contact accidontel do lOlectrode avec des objets metalliques pout provoquer des Øtincelles, une explosion, un surchauffemont ou un incondie. Avant do commencer le soudage, verifier et sassuror quo lendroit no prØsento pas do danger. Le soudage personnes do Ia So proteger ot dautres metal chaud. projection dOtincelles Ne pas souder dana un endroit l oU dos Otincellos sur des substances inflammables. Porteursdestimulateurcardiaque, restez distance. Los porteurs dun stimulateur cardiaque doivent dabord consulter leur mØdecin avant de sapprocher des operations de soudage a larc, de gougeage ou do soudage par points. et do pouvont tomber DØplacertoutos los substances inflammables a uno distance do 10,7 m do larc do soudago. En cas dimpossibilitØ los recouvrir soigneuso mont avec dos protections homologues. Des Otincelles et dos matØriaux chauds du soudage peuvent facilemont passer dans dautres zones en traversant do petites fissures ot LEkBRUITPeUt affectØ~r . Lo bruit des processus et des IouIe. Porter des _______________ Powe equipoments peut affecter protections approuvØs pour los oreilles 51 lo nivoau sondre est trop ØlevØ. des ouvorturos. SurveillertoutdØclenchementdincondio ottonirunoxtincteuraproxi mite. ~SIdes - ~ Le soudago effectuO pout dØclencher un Ne pas offectuer 10 sur un plafond, plancher, paroi incondie do lautre ctØ. soudago reservoirs, tambours, ou sur rØs corroctemont conformØmont a AWS F4.1 (voir los normes sous do 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. poste Des boutoillos do gaz protecteur contiennent du gaz haute prossion. Si uno boutoille est endomma gee, 0110 pout oxploser. Du fait quotes bouteilles do gaz font normalement partie du procØde do soudago, los des contoneurs fermŁs tels quo dos conduites, a moms quils naiont etO prØpa securite). No pas utiliser le lees. qØes, eIiespourro~ipj~e~_ separation ou do soudage pour degolor dos conduitos go En cas do non utilisation, enlevor Ia baguette dØlectrode electrode ou couper 10 fil a Ia pointe do contact. du porte vos 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 debout en los fixant dans un support station nairo ou dans un porte-bouteilles pour los empØcher do tomber ou do so renverser. Tenir los boutoilles Porter des vŒtemonts do protection depourvus dhuilo tels quo des gants on cuir, une chemise en matØnau lourd, des pantalons sans re vors, dos chaussures hautes ot un couvro chef. Avant do souder, retirer toute substance combustible do tollos quun allumeur au butane ou dos allumettes. manipuler avec precaution. poches ~~RTICULESVOLANTES.. eloctriques. jamais placer eloignees No une Uno electrode do une bouteillo. No jamais souder Porter des lunettos do sØcuritØ 6 avec Øcrans latØraux ou Un torche do soudage soudage ou autres cir uno ne bouteille soudago sur uno jamais ontrer doit pressurisee boutoille a gaz. en contact avec 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 tŒte boutoillo. Lo soudago, lØcailloment, le passage do Ia piŁce a Ia brosso en fil do fer, ot le moulago generont des Øtincellos ot dos particules metalliques volan tes. Pendant Ia periodo do ref roidissomont des soudures, ollos risquont do projeter du laitier. dos circuits do cuits on face do Ia sortie en ouvrant Ia soupape do Ia Maintenir le chapeau do protection sur Ia soupapo, sauf dutilisation ou do branchement do Ia bouteille. en cas Lire et suivro los instructions concemant los bouteilles do gaz cornlos equipements associØs et los publications P-i CGA Ønu mØrØes dans los normes do sØcuritØ. prime, Øcran facial. OM-167 439 t3 Dangers supplØmentaires en relation aitec rinstallation, iu~n~ima ~1 :~ 1__~J le etlamainfenance peu~i DES ORGANES MOBILES Ne pas placer lappareil sur, au-dessus proximitO de surfaces infliammables. ou a Rester a lecart Maintenir fermes et fixement Ne pas installer lappareil a proximitØ de produits inflammables Ne pas surcharger linstallation Ølectrique sassurer que lalimen tation est correctement dimensionnØ et protØgØ avant de mettre lappareil en service. DAREIL panneaux, Utiliser un engin dune pour et place les portes, dispositifs de Le rayonnement haute frequence peut provoquer des interferences avec les Øquipements de ra dionavigation et de communication, es services de sOcurite of les ordinateurs. Demander seulement a des personnes qualifiees familiarisees des equipements Olectroniques de faire fonctionner linstalla tion. avec lappareil. En utilisant des fourches de levage pour deplacer lunitØ, sassurer que les fourches sont suffisamment longues pour depasser du cafØ oppose de lappareil. LEMPLOI en recouvrements LE RAVONNEMENt~ HAUTE~YFRE-: OUENCE4H F) risque de provoquer de SM t$reSES :.*HY:~*J peut capacitØ appropriee EXCESSIF peut SURCHAUFFERLEQUIPEM ENt PrOvoir une pOriode de ref roidissement, respec ter le cycle opOratoire nominal. Reduire le courant ou le cycle le soudage. Lutilisateur est tenu de faire corriger rapidement par los interferences resultant de linstallation. -~ un electricien qualifiO des interferences, arrOter immØdiatement Si le FCC reil. signale Effectuer reguliŁrement le controle et lentretien lappa 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. opOratoire avant de recommancer Ne pas obstruer les passages dair du le comme protection. Utiliser lanneau de levage uniquement pour sou lever lappareil, NON PAS les chariot, les bouteil les de gaz ou tout autre accessoire. soulever des organes mobiles vent ilafeur. de. poste. HARGES ELEItbsT ATIQUS de Lenergie electromagnetique risque provoquer des interferences pour lequipement electronique sensible tel que les ordinateurs et lequipement commande par ordinateur tel que itenornmager Ies.cfrcu Its !. los robots. Etablir Ia connexion avec Ia barrette de terre avant de manipuler des cartes ou des piŁces. Utiliser des pochettes pour stocker, dØplacer circuits imprimes. et des boltes ou antistatiques expOdier des cartes de :s ORGANES MOBILES es 4es bies YP~q Ne pas sapprocher peuvent i: des organes mobiles. Ne pas sapprocher des points de coincement tels que des rouleaux de commande. Veiller ace que tout lequipement de Ia zone de soudage soit com patible electromagnetiquement. Pour reduire Ia possibilite dinterference, maintenir les cables de soudage aussi courts que possible, les grouper, et los poser aussi bas que possible (ox. par terre). Veiller a souder a une distance de 100 metres de tout equipement electronique sensible. Veiller a ce que ce poste de soudage soit pose et mis a Ia terre conformement a ce mode demploi. En cas dinterferences apres avoir pris les mesures precØdentes, il incombe a lutilisateur de prendre des mesures supplØmentaires telles que le deplacement du poste, lutilisation de cables blindes, lutilisation de filtres de ligne ou Ia pose de protecteurs dans Ia zone de travail. ::tES~nLS0ESQUbAGE peuvent pro :St!piUIathi4r~cardlaques; ~..voq!ft~s blessures. Porteurs de stimulateur No pas appuyer reu linstruction. Ne pas sur Ia gachette avant den avoir le pistolet vers soi, dautres per sonnes ou toute piŁce mecanique en engageant le fil de soudage. OM-167 439 diriger cardiaque, restez a dis tance. Les porteurs dun stimulateur cardiaque doivent dabord consulter leur mOdecin avant de sappro cher des operations de soudage a larc, de gou geage ou de soudage par points. 7 A Principales normes iesØcuritØ Safetyin Welding and Cutting, norme ANSI Z49.1, de lAmerican ding Society, 550 N.W. Lojeuno Rd, Miami FL 33126 Safetyand Health Sandards, Wel OSHA 29 CFR 1910, du of Documents, U.S. Government 20402. Superintendent Printing Office, Washington, D.C. Regles de sØcuritØ en soudage, coupage etprocOdOs connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente de normes, 178 Roxdale Boulevard, Rexdale (Ontario) Canada M9W me 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. 1 5 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. Safe information suries 1R3. 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. champs electromagFnetlques DonnØes sur le soudage electrique et sur les effots, pour des champs magnØtiques basso frØquence lorganisme, Afin do rØduire les de travail, champs electromagnetiques dans lenvironnemont respecter los consignos suivantes Garder los cables ensembles en los torsadant avec du ruban adhOsif. Loxtrait suivant est tire des conclusions generales du document intitu 6 Biological Effects of Power Frequency Electric & Magnetic Fields 1 (Washington DC: U.S. Govern Background Paper, OTABPE53 Printing Office, mai 1989), publiØ par le Office of Technology Assessment du Congres amØricain: ... 1 existe maintenant dabon dantes donnOes 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 et memo y produire des vent avoir des offets sur lorganisme transformations. MŒme sil sagitde travaux de trØs grande qualitØ, les rØsultats sont complexes. Cette dØmarche scientifique ne nous per- 2 Mottro tous los cables du ctØ 3 Ne pas courber pas et ment met pas dØtablir un tableau densemble coherent. Pire encore, elle ne no oppose do lopØratour. pas entourer pas los cables autour do vous. 4 Garder le de 5 poste de soudage et los cables le Relier Ia pinco do masse lo plus prŁs possible Consignes relatives aux stimulateurs Veuillez consulter votro mØdecin pour obtonir 8 (Traduction Iibre) possible de Ia zone do cardiaques rØduire sinon Øliminer los Øventuels. loin soudure. Les risques plus vous. permet pas de tirer des conclusions finales concernant les ris ques Øventuels, ni doffrir des consoils sur los mesures a prendro pour nous los ou en attachant consignes mentionnØes precedemment font partio de celles desti nØos aux personnes ayant rocours a un stimulateur cardiaquo. plus do details. OM-167 439 2. Definitions Generat 2 1 Precautionary Label ~ 1/96 Watch Out! There Warning! hazards possible shown as are 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 or wear wet damaged gloves. yourself from electric by insulating yourself work and ground. 1 .2 Protect shock from 1.3 Disconnect input plug power before machine. 2 working or on 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 2.3 Use remove ventilating fan the fumes. to remove fumes. 3 Welding sparks can explosion or fire. 3.1 Keep flammables away from welding. Do not weld near cause 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 Arc rays can burn eyes and injure skin. 4.1 Wear hat and safety glasses. protection and button shirt collar. Use welding Use ear helmet with correct shade of filter. Wear complete body protection. 5 Become trained and read the instructions before working the machine or welding. on 6 Do not remove or (cover) the label. OM-167 439 paint over 9 2 2~ ~Manufaotu~rers Rating 1T1_1T11 Labels 380 Volt Models 415 Volt Models EN 60974-1 EN 60974-1 20A/1 0.8V 180 All 7V 20A/1 0.8V 1 80A11 7V 30A/11.2V 165Al16.6V 30A/1 1 .2V 1 65A/1 6.6V 20A/20.8V 1 70A/26.8V 20A/20.8V 1 70A/26.8V 30A121.2V 380V Ui 44A imax 135A/25.4V left 30A/21 .2V 16A 415V U1 IP 23 3... left 15A IP 23 Tig Welding ~It~ Output ~\J~ A ... A Amperes ~J Amperage Control/ Panel U0 I 1 max Rated No Load Voltage (Average) Rated Maximum Supply Current Percent Remote Footl Stick Hand Control Alternating Current / Electrode Electrode Positive , 10 40A SymhotDefinitions~. 2~3:. + imax 135A/25.4V U2 2 U1 Negative Welding High Temperature Direct Current On Do Not Switch Under Load Voltage Input Off Electrode (~3.* Gas Out Work Remote ~( Volts Conventional Load Voltage Rated X left Combined AC/DC Power Source Protection ~J ~ Line Connection Maximum Effective Supply Current Single-Phase Degree Of Welding Current Primary Voltage Duty Cycle liz Hertz OM-167 439 3. Introduction Included with Your Unit ~3 1 1 12 ft (3.7 m) Work Cable and Clamp 2 150 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) 3 Electrode Holder and Quick-Connect 4 Gas Hose 5 Gas Regulator (Not included with 50 Hz mod els) 6 How-To 7 Foot Control with 20 ft (6 m) Cord (60 Hz models only. Videotape 50 Hz and other models applicable come with Fingertip Control instead.) (2.4 m) Primary Cord (Plug supplied with 230 Volt model only) 8 ft 8 fT Some assembly is required. options and accessories back of book or contact your distributor. For see SpecificatIons~ 132 Max,~ Rated Output at Duty Cycle T(G: (GTAW) Stick: (SMAW) While 20% Open-Circuit Voltage Welding Amperage Range AC High AC Low DC 15OAat15VDC 15OAat15VAC TIG Welding 50165 2050 130 A at 25 VDC 150 A at 25 VAC 35165 Stick A Welding Range Net Rated 380 V-39 A 78 30160 A 2050 Output 415V36 Range A KVA Dimensions 14.8 0.64 78 Weight H: 18 in (457 mm) W: 13 in (330 mm) D: 251/2 in 140 lb (64 kg) (648 mm) 25130 idling. ~ Duty Cycle ----~. -~ -~:~ ...:. Chart -. \ ST:157648.A 100 0 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. 10 II SO 40 50 GTAW: 20% SMAW: 20% Duty 150 A AC Duty Cycle Cycle at 150 A AC/DC at 130 A DC, or IO~SOIO~0 x DUTY CYCLE OM-167 439 2 Minutes 8 Minutes Welding Resting 11 -::v - .:Y~ .~ nr .~T~VtflrrqT$rrt~- ~ J Volt-Ampere Curves :~i. ___ Volt-ampere curves ssbl.1 10/91 mini show ST-157 625-B / ST-157 626-B voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves mum and maximum shown. 70 70 ~\ 60 U, A :L~0w RANX RAh~ 80 ~2w \ ~40 r\ Sr \\ 20 t 1C I>\ I \i ZJ A 10 i1I ~ ~ I I tO 150 2(X) 250 0 0 50 0 3W 0 50 100 150 250 2W 3W DC AMPERES APvFERES AC 4. Installation Selecting a :.~iL~i Position unit air so can Location -~ . ..~1 ~ ~ - 4 1 - - - ~ -a:.~)::L~:~~-...a az - ST-158 075 circulate. For information about- sources of see Section 8. - high-frequency For carts and caster kits of book or see back 18 in contact your distributor. 18 in (460 mm) (460 mm) tar .~ 42 - a arrzI~rrt~~ ~ .: - - -:~~---. a:-:~ ----~tr Typical StlcI Connections :a..::.~ .:... ST-157 858-A 1 Electrode Holder 2 Work Clamp Connect to receptacle as shown. 1 12 OM-167 439 i~3 TIG Connections Typical ~~ 1 Remote Control 2 Torch 3 Work Clamp Connect to 4 Ref. ST157 858-A receptacle shown. as Cylinder Chain gear, or secure wall, or cylinder to running other stationary support. 5 Cylinder Open valve Valve slightly so gas flow blows dirt from valve. Close valve. 6 Regulator/Flow Gauge Install 7 so Flow face is vertical. Adjust Typical flow rate is 20 cfh feet per hour) (9.4 L/min). (cubic 3 Tools Needed: 5/8,1-1/Bin OM-167 439 13 4~4 ElectricalServuce Guide S-0092J Input Voltage Input Amperes at Rated Standard Fuse or Output Circuit Breaker Rating (Max. Recommended) Input Conductor Size (Mm.) Conductor Size Connecting Input A Have only qualified persons make this installation. A Special installation may be required where gasoline or volatile liquids are present NEC Article 511 Section 20. see or 39 36 Amps 151 ft (46 m) 12 AWG (Mm.) Reference: 1996 National Electrical Code ~4 5 415 12 AWG Input Conductor Length (Max. Recommended) Grounding 60 380 50 Amps 12 AWG 181 ft (55 m) 12 AWG (NEC). Power CEC Units come equipped with input power cord for installation into line disconnect device. Select type and size overcurrent protection using Section 4.4. GND/PE L2 14 OM-167 439 5. Operation ~TSii~II1 -\ Ref. ST-173 373-B 1 Weld Process Switch Use switch to select weld process. In Stick position (down), weld output goes On and 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 bilize welding arc starter. 2 3 when needed to start or sta arc. No adjustments needed for comes on Pilot Stick (SMAW) Table Use table to find approximate Stick amperage output at Amperage control setting. See Section 5.2 for exarr pie of front panel am 5 Current Direct use Electrode Electrode Negative Negative position. For Direct Current Electrode Positive Electrode Positive position. (DCEP), use For alternating current (AC), ed for welding application High position see range need or AC use AC Low Warning. perage control. For remote amperage control used when TIG (GTAW) welding, front panel Amperage con trol setting is the maximum amperage percen at the remote control device. See Section 5.3 for age control. Power Switch unit, fan, and pilot light On and Off. 6 Range/Polarity exarr pIe of remote amper See Section 5.4 to find output for application. 7 High Temperature suggested type of weld Shutdown Light Amperage Control output. Lights when unit overheats and shuts down (see Section 6.2). 8 Switch Use switch to select range and 4 For (DCEN), tage available Light Use switch to turn For Stick (SMAW), use control to adjust am perage within range sel3cted by the Range/ Polarity Switch. polarity of weld Output On (Contactor) Light Lights when output (contactor) and unit power are on. 2 3 8 5 ~ AMPERP~ VS. D~*L% S LOW N I~U~l DC $4 !. $ $0 24 22 24 24 40 II 40 24 10 $4 24 23 SO 21 71 10 $2 $0 $7 ~4 U SO 4$ ~I I~ 100 50 III 4$ $4 7 4 OM-167 439 15 52 Exampe Amperage ofFronl Panel Control 0 \., 34$ 18-50A ~MA~ OU~UT AMPERP~ YB. DIAL X VS Z 60 AC LOW ~ii Xe A IS 23 IS 39 24 21 46 25 24 69 27 79 43 10 82 80 31 ~4 55 43 151 113 60 156 ~ ~ 100% DC f i~ 0 AC HS~I U ____ In Example: Range DC Percentage of Range Weld Amperage 33 ] = Select weld process. Exampe Select range and of Remote Select polarity. percentage. = = 50% A DC Amperage Control o \ila-50A ~. I 3~1~ 60 20 Xe Select weld process. Select range and polarity. ..........) GTAW Select percentage. .....14 Welding Amperage Range AC Low AC High DC or -, 20-50A 60-165A In Example: Range DCEN Percentage of Range 30-165A = Connect remote control 16 (see Section 4.3). 50% Remote weld amperage 3098 A DC (50% of 30165 A DC) = = OM-167 439 Pi~cess 5~4 and Material Thickness Guide Label N Guideline For Welding Process And Output For Material Material Thickness Material And Weld Output 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 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 Steel Or Stainless Steel () 6 ga 0.186 in 4.8 mm 2 ga 0.25 in 6.3 mm 0.25+ in 6.3+ mm SMAW A DCEN Sl. . GTAW ELECTRODE NEGA11VE With DCEP Output ~ Aluminum Difficult ~ Recommended AC S-167 338 OM-167 439 17 G. Maintenance and TroubleshootiNg 61 Routine Maintenance A S ~ Maintain ~ maintaining. Disconnect power before more often during conditions. severe 3 Months Replace unreadable labels. Clean and tighten weld terminals. Replace 0-ring ~fl Electrode/Gas Output receptacle if cracked. 6 Months Blow out or vacuum inside. Or 62 Troubleshooting Trouble No weld Remedy output; fan does not run. Place line disconnect switch in On Check and replace Check for proper No weld output; fan Be on. sure Tighten fuse(s), line if necessary, Range/Polarity remote control connection to Remote 14 Check for and Have 18 reset circuit breaker switch is not set between (see (see Section 4.5). remove positions. receptacle. remote control Owners Unit overheated. Allow unit to cool output or input power connections (see Section 4.5). Check remote control Fan not operating; weld available. position (see Section 4.5). (see Section anything blocking Factory Authorized Service Agent Manual). 3.3). fan movement. check fan motor. OM-167 439 .:: 7. Electrical Diagram ~rrs~~?:::::::::.::.:.~: 71 ~ ~ Circuit Diagram ~ ~~+-~- ~C..................:.... . DTr., . ~1 .szna~ SB-154 141-C 230 VAC OM-167 439 19 8. High Frequency WeIdin~P~oceSs~Requiring~.Hi 81 high_freql 11/96 S-0693 1 1 High-Frequency Voltage Helps arc jump air gap between and/or workpiece torch and stabilize the arc. TIG 8~2 Incorrect Installation, N. N. S-0694 Sources of Direct Radiation 1 High-Frequency High-Frequency Source (welding power source with built-in HF or unit) Sources of Conduction of Frequency 7 Input Power Torch 4 Work 5 Clamp Workpiece 6 Work Table Sources of Reradiation of High Frequency Cable 13 Ungrounded Metal Objects Lighting Wiring Water Pipes and Fixtures 14 External Phone and Power Lines 10 8 Line Disconnect Device 11 9 Input Supply Wiring 12 2 3 High ~-------Weld Zone--~ 5Ott (15 I /1 (I N 20 7 OM-167 439 Correct Installation .:.. ~ .: .. Ret S-0695 I Ret S-0695 High-Frequency Source (welding 1 power source with built-in HF 5 Conduit Joint Bonding and Grounding Electrically join (bond) all conduit sections using copper straps or braided wire. Ground separate HF unit) Ground metal machine case, work output line disconnect device, input supply, and worktable. conduit every 50 ft (15 rn). terminal, Center Point of 2 between Midpoint Welding Zone high-frequency welding torch. Welding Zone circle 50 ft (15 m) 6 Water Pipes Ground water source 7 and Fixtures External Power A from center Weld point Keep in all high-frequency (15 m) away from power Grounding Consult the together. and phone lines. Building Panel Bonding Methods Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame. Windows and Doorways and doorways with grounded copper screen of not more than 1/4 in (6.4 mm) mesh. 11 8 Output Cables cables short and close Building Requirements Metal Cover lŁlephone Lines ~ource at least 50 ft Locate directions. 4 or 9 10 pipes every SOft (15 m). and 3 Metal or all windows Overhead Door Track Rod National Electrical Code for Ground the track. specifications. Weld Zone ~ ________ Metal OM-167 439 Building 21 ~oc~ _.L ~) ~ 1< CI) 13 10 9 26 8 5 48 38 36 II 0 CO. CD > Item No. Part No. Dia. Mkgs. DescriDtion Quantity 154 335... BEZEL, front 1 176254... LABEL, warning +165 986... WRAPPER 2 3 PCi 4 Fl .... .... 1 1 general precautionary 186 172... CIRCUIT CARD, arc sta~control *012 658 FUSE, mintr gi sb-bID 2A 1 (consisting of) I 1 PLG1,6... 130203... CONNECTOR & SOCKETS 5 134 201 6 155 404... 7 603 106... ... 2 STAND-OFF SUPPORT, PC card .312/.375 4 BRACKET, mtg components 1 3ft 10 HOSE, nprn brd No. 1 (order by ft) 010 865... CLAMP, hose .430-.515 clp dia 125 785... VALVE, 24VAC 2 way custom port 1/8 orf 605227... NUT, nylon hex jam .75ONPST 11 147571 8 9 .... GS1 .... ... 155399... PANEL, 13 605 077... 15 SRi 154 849 C4,R3... 156 237 151880 154 696 119 351 19... 1 2 1 rear 8ft CABLE, port No. 10 3/c (460V Model) (order by ft) 044426... CONNECTOR, clamp cable .690/1.070 154848... RECTIFIER, si diode (consisting of) 154 695 RECTIFIER, straight polarity (consisting of) 119 607 17 I HANDLE 12 14 2 1 1 1 DIODE, rect 35A 1000V RP BUS BAR, rectifier 2 CAPACITOR/RESISTOR CAPACITOR 4 RECTIFIER, reverse polarity (consisting of) DIODE, rect 35A 1000V SP 6 6 1 1 VR1,R2... 044482... SUPPRESSOR 150783... BLADE, fan 9 in .312 hub FM 148 808... MOTOR, fan 230V 1550RPM .3l2dia shaft 155 403... BRACKET, mtg fan & rectifier Zi 155469... STABILIZER Ti 161 389... TRANSFORMER, pwr main 380V 161 390... TRANSFORMER, pwr main 415V Ti TP1,2 1 1 1 1 1 1 (consisting of) (consisting of) THERMOSTAT,NC 083 147... GROMMET, screw No. 8/10 panel hole .312sq 034 260... LINK, connecting contactor terminal 1 176170 2 .500 4 high 2 W 035519... CONTACTOR C2 155 501 Cl 155 290... CAPACITOR 1 2 T2 155 107... CABLE TIE, push mount 0-1.500 bundle 157 596... TRANSFORMER, impLilse HV Z2 155 499... ... 159 102 155 288 Si Elec Ri 124 511 ... 1 CAPACITOR 1 1 TRANSFORMER, blocking (consisting of) PLATE, mtg block transformer COIL, blocking SWITCH, tgl DPST 40A 600VAC 1 1 1 1 165987... BASE I 186 092... RECEPTACLE KIT, dinse 035 897... POTENTIOMETER, C sltd iT 2W 1K ohm 1 1 134 900... STRAIN RELIEF, cable flex .270-.480 cable ...39....RC1.... 143 976... CONNECTOR w/SOCKETS 134 734... CONNECTOR, circ 14 pin plug Amp 213571-2 134 731 CONNECTOR, circ pin push-in 14-l8ga Amp 213603-1 079 739... CONNECTOR, circ damp str rlf sz 17-20 Amp 206322-2 143 922... CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3 1 1 ... 097 924... KNOB, pointer PL3.... 155 500... LIGHT, indicator 148 956... HANDLE, switch PL2.... 157 957... LIGHT, md blu lens 28V snap mtg OM-167 439 (or) 1 1 1 1 23 9.1 Item No. (Continued) Dia. Part No. Mkgs. S3 155013... PL1 .... 47 S2 S4 SWITCH, rocker SPST 1OA 25OVAC Quantity 1 NAMEPLATE, (order by model and serial number) 1 LIGHT, md wht lens 28V 1 155422... PANEL, front 1 154896... SWITCH, polarity (consisting of) SWITCH, urn hA 125V roller lever actr CABLE, weld/cop strd No. 4 (order by ft) BODY, electrode holder SPRING, cprsn .490 OD x .090 wire LEVER, clamp electrode holder HOSE, gas 1 157958... 089645... 600317... 028594... 025475... 028593... 128188... 1 l5ft 1 1 1 1 128434... REGULATOR/FLOWMETER 1 CONNECTOR, twlk insul male 010368... CLAMP, work 200A 026843... INSULATOR, vinyl black 1 134460... +When Description 1 2 component originally displaying a precautionary label, the label should also be ordered. 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. * ordering a Recommended 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 rack. cylinder RHC-1 4 Hand Control #129 340 Miniature hand control for remote current and contactor control. Dimensions: 4 in (102 mm) (102 mm) x 3-1/4 in (82 mm). 20 ft (6 m) cord and 14-pin plug. Includes x Universal Carrying Cart and Cylinder Rack 4 in #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 welding (31 kg). rod tube. Net one shipping weight is Stick 69 lbs 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. 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. Includes 28 ft (8.5 m) cord and plug. Allows complete current and contactor control. OM-303 Effective January 1, 1997 (Equipment with a serial number preface of RH This limited warranty supersedes all guarantees or or newer) previous Miller warranties and is exclusive with warranties expressed or implied. LIMITED WARRANTY Subject to the temrs and conditions Miller Electric Mfg. Co., Appleton, Wisconsin, its 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 INCLUDING IMPLIED, THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Millers True Bluefi Limited below, Warranty no other shall not apply to: warrants to 1. any. 2. 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 warranty claim procedures to be followed. on the Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal 3. wear. Equipment that has been modified by any party other 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 than 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, year after the equipment is sent to a North American distributor or eighteen months after the equipment Is sent to an International distributor. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These Items are covered by the manufacturers warranty, If specifications for the equipment. or one MILLER PRODUCTS ARE INTENDED FOR PURCHASE COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. AND USE BY 1. 5 Years Parts3 Years Labor Original main power rectifiers Inverters (input and output rectifier; 2. 3 Years * only) Parts and Labor Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Warranty Questions? Intellitig * Robots * Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) Call 1 -800-4-A-MILLER 3. 1 for your local Miller distributor. Supplies * YearParts and Labor * Motor Driven Guns * Process Controllers * TO THE EXTENT PERMIUED 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 Positioners and Controllers Automatic Motion Devices CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF Orbital Weld Heads * PROFIT), WHETHER BASED ON ANY OTHER LEGAL THEORY. IHPS Power Sources Water Coolant REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY Spot Welders Load Banks OTHER SDX Transformers * Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT, PLAZCUT Models) Deutz Engines (outside North America) ZIPCUT & 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 5. 90 Days Batteries APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches w The Power ofBbi. Remote Controls * THEORY WHICH, BUT FOR THIS 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 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. an Parts and Labor MIG Guns/TIG Torches f//A Miller LEGAL PROVISION, Miller 4. TORT OR ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR Grids * CONTRACT, Systems HF Units * In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Millers 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 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. Accessory Kits Replacement Parts (No labor) 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. milIer_warr 3/97 .,::,::::~:~~ ::. ~~a flt_ Owners Record \ \ ~. .~ <~ ~ :;~ ts~t&. ~ ta~s ~ ~ ~flSs~ ... ~. ~ ~ ~ ~~ k Please complete and retain with your personal records. nv~tt~ ~ ttZS~~\ t~t~~rP$s~ ;~ ~q ~. ~pwiz~ :~ _~~-~ ~ ..~& Model Name ~ ~ ~ ~t~ms ~ Serial/Style Number ~ (Date which equipment delivered to was ~ ~ original customer.) ~ .~ ~. ~ Purchase Date ~ ~ ~ W5~\~fl.fl~t.. N . 11w1r9 ~k\ k~s~ ~ ~ Distributor ~ Address ~ p*~ ~$+&~ ~n City ~Ich~ ~ ~ ?W s ~ ,:_ :::___E. __~~:~ r~:-~c~~ ~__ :~N~ __~~ ~ ~: _:: T~ ::~: ~ N2 : ~, -:-t . ~ - - ~p s~8r ~ ~ ~ ~ ~~~?:N : ~ ,,. ~ ~. ~ :~:~: ~:::::: ~ :-:-~ -: ::::.-:::i : ~ N~-~ :::- :- ~ j~W4~.t-~L~ ~N: NrN~~ N:: :.:. ~ - Zip - State ~N ~ 1s~N~N~ ~NV ::: ~: - ~ ~ - l~Wrk ~CE aat~:t ~flta~.\ ~ te - ~ ~, ~ Resources Available ~~ ~ ~ ~ -~. :.~ -: - ~ ~~(/~fl a~ flt;&~ ~ ~S~nak~4t , :~: ~: :~::::- Sn -- ~ ~ Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies To locate distributor nearest you call Options and Accessories and Consumables - :-:: H. 1-800-4-A-Miller. Safety EquIpment Repair Replacement Parts --: - Service and - Personal Training (Schools, Videos, Books) Owners Manuals Technical Manuals and Parts) Circuit (Servicing information \1~ ~rn~ Diagrams Welding Process Handbooks W~ ~ ~ Contact the DeliverIng Carrier for: File a claim for loss or damage during ship - ment. ~.. H:: - ~ For assistance in filing or settling claims, contact your distributor and/pr equipment - - - - - - :~H manufacturersTransportation Department. I/I -- .7 PRINTED IN USA ' 1996 Miller Electric Mtg. co.
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