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OM-303 155 795T
May 2005
Processes
Gas Tungsten Arc
(TIG) Welding
Shielded Metal Arc
(Stick) Welding
Description
Arc Welding Power Source
Econotig
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Insta
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Notes
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux Identifie un message de sécurité particulier. PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symboles et
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LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation. tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien ventiler les espaces confinés ou porter un
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2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. Ne pas placer l’appareil sur une surface inflam- Se tenir à l’écart des organes mobiles comme les mable, ni au −dessus ou à proximité d’elle. ventilateurs. Maintenir fermés et bien fixés les portes, Ne pas installer l’appareil à proximité de produits inflammables. panneaux, recouvrements et dispositifs de
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2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463 −6727 ou à Toronto : (416) 747 −4044, site Web : www.csa−interna- (téléphone : (305) 443 −9353, site Web : www.aws.org). tional.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protect
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SECTION 3 − DEFINITIONS 3-1. General Precautionary Label OM-303 Page 9
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3-2. Symbols And Definitions Remote Foot/Hand Tig Welding Stick Welding High Temperature Control Output Alternating Current Direct Current On Electrode Do Not Switch Electrode Positive Voltage Input Negative Under Load Amperes Off Electrode Gas Out A Amperage Control/ Work Remote Volts Panel V Rated No Load Conventional Load Maximum Effective Duty Cycle U Voltage (Average) U Voltage X I Supply Current 0 2 1eff Single-Phase Rated Maximum Rated Welding Degree Of 1 1 1 1 Combined AC/DC I Supply Cur
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4-2. Specifications A. 60 Hertz Models Rated Output at 20% Duty Welding Amperage Range Max. Rated Output KVA KW Dimensions Net Cycle AC High AC Low DC OCV Weight TIG: 150 A at 15 VDC (GTAW) 150 A at 15 VAC 50 −165 20 −50 30 −160 200 V −60 A (3.6)* 12.0 5.4 H: 18 in (457 mm) 140 lb (64 kg) (64 kg) 78 78 230V 230V − −52 A (3 52 A (3.0) 0)* * (0 (0.64) 64)* * (0 (0.3) 3)* * W W: : 13 i 13 in (330 mm) n (330 mm) Stick: 130 A at 25 VDC 1 460 V −33 A (1.5)* D: 25 / in (648 mm) 2 (SMAW)
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SECTION 5 − INSTALLATION 5-1. Selecting a Location Position unit so air can circulate. For information about sources of high-frequency see Section 9. 18 in For carts and caster kits see back 18 in (460 mm) of book or contact your distributor. (460 mm) 18 in (460 mm) ST-158 075 5-2. Typical Stick Connections Turn Off power before mak- ing connections. 1 Electrode Holder 2 Work Clamp Connect to receptacle as shown. 1 2 ST-157 858-A OM-303 Page 12
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5-3. Typical TIG Connections Turn Off power before mak- ing connections. 1 Remote Control 2 Torch Connect to receptacles as shown. 6 3 Work Clamp 4 Cylinder Chain or secure cylinder to running 5 gear, wall, or other stationary 7 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 cfh (cubic feet per hour) (9.4 L/min). 4 1 2 3 Tools Needed: 5/8, 1-1/8 in Ref. ST-1
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5-4. Electrical Service Guide S-0092J For 230 V models with wall receptacle, 100% duty cycle used to calculate data below. 20% duty cycle used for all other models. Input Voltage 200 230 380 415 460 Input Amperes At Rated Output 60 52 39 36 33 1 Max Recommended Standard Fuse Rating In Amperes 2 Time-Delay 70 60 45 40 30 3 Normal Operating 90 80 60 50 40 4 Min Input Conductor Size In AWG 10 6 12 12 14 42 135 Max Recommended Input Conductor Length In Feet (Meters) 151 (46) 181 (55) 85 (26) (13)
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SECTION 6 − OPERATION 6-1. Controls 6 1 2 3 8 5 7 4 Ref. ST-155 790-F 1 Weld Process Switch For Stick (SMAW), use control to adjust amper- For Direct Current Electrode Negative age within range selected by the Range/Polar- (DCEN), use Electrode Negative position. Use switch to select weld process. ity Switch. For Direct Current Electrode Positive (DCEP), In Stick position (down), weld output goes On 5 Stick (SMAW) Table use Electrode Positive position. and Off with Power switch. Use table to fin
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6-2. Example of Front Panel Amperage Control In Example: Range = DC Percentage of Range = 50% Select weld process. Select range and polarity. Select percentage. Weld Amperage = 33 A DC 6-3. Example of Remote Amperage Control Select range and polarity. Select percentage. Select weld process. GTAW Welding Amperage Range AC Low AC High DC or 20-50 A 60-165 A 30-165 A In Example: Range = DCEN Percentage of Range = 50% Remote weld amperage = 30 −98 A DC (50% of 30 −165 A DC) Connect remote control. O
