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OM-611 096 556U
January 2004
Processes
TIG (GTAW) Welding
Description
High Frequency Arc Starter
HF-251D-1 And HF-251-2
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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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 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 necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding Ha
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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 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 li
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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. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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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 American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection, ting of Containers
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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 N
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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 Protection
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SECTION 3 − INSTALLATION 3-1. Specifications Welding Input Power Type Of Input Power Dimensions Weight Circuit Rat- Circuit Rat- Cord With Cord With 115 Volts 230 Volts Height Width Length 115 Volts 230 Volts ing Plug 115 Volts AC 230 Volts AC Net: Net: 250 Amperes Single-Phase Single-Phase 15 in 9-1/4 in 16 in 34 lb (15 kg) 36 lb (16 kg); At 60% Duty 10 ft (3 m) (381 mm) (235 mm) (406 mm) 50/60/100 Hz, 50/60 Hz, Ship: Ship: Cycle 1.5 Amperes 0.75 Amperes 37 lb (17 kg) 39 lb (18 kg) 3-2. Typical
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3-3. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- ary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. 1 Close valve. 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 5 Gas Hose Connection 6 Fitting has 5/8-18 right-hand 2 threads. 6 Flow Adjust Typical flow rate is 15 cfh (cubic feet per hour). Make sure flo
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The supplied cord with plugs is for use with CC or CC/CV welding power sources NOTE having the proper, matching 14-pin receptacle. Do not use cordset on machines without the 14-pin receptacle. 3-4. Power Source Plug Information And Connections Turn Off HF Unit and welding power source, and discon- nect input power before making connections. Stop engine on welding genera- 5 tors. 1 Six-Pin Power Source Block Plug PLG2 Connect Remote 14 Plug PLG4 if remote 2 Supplied Six-Pin Receptacle J A
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3-5. Operator Control Receptacle Information And Connections 1 Operator Control Receptacle RC1 (See Section 3-6) 2 Keyway 3 Plug 4 Threaded Collar To connect to receptacle, align 12 keyway, insert plug, and tighten threaded collar. AJ K I B L NH C M D G F E 4 3 The 14-socket Operator Control receptacle RC1 on the front of the high- frequency unit is used to connect an optional Amperage Control and/or a remote start switch to the control circuitry of the high-frequency unit. If this unit is used
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3-7. Connecting To Weld Output Terminals Turn Off HF Unit and welding power source, and discon- nect input power before making connections. Stop engine on welding genera- tors. Not connecting work cables to HF Unit will damage power source. Always connect work cables to Work Input/ 12 Output terminal. 1 Electrode In Terminal Open left side panel. Connect elec- trode cable from welding power source to Electrode-In Terminal. ELECTRODE IN ELECTRODE OUT 2 Electrode Out Terminal Connect torch ca
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3-8. Connecting Input Power Read and follow entire Sec- tion 8 about HF equipment be- fore installing unit. Direct Current (DC) will dam- age HF Unit. Connect unit only to Alternating Current (AC) supply. Do not cut grounding terminal off plug. 1 Grounded Receptacle See Section 3-1 for type of input power required. 2 Plug From Unit Insert plug into receptacle. 1 2 Ref. 159 606-B / Ref. 149 354-A OM-611 Page 14 Return To Table Of Contents
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SECTION 4 − OPERATION 4-1. Controls 1 Power Switch 2 Pilot Light 3 High Frequency Selector Switch 12 3 4 High Frequency Switch 5 High Frequency Intensity Control 4 5 Ref. 098 956-D 4-2. High Frequency Switch 1 High Frequency Switch 1 Start − provides HF for arc starting only. Off − provides no HF. Use Off for SMAW welding. Continuous − provides HF continu- ously. Ref. 139 573 4-3. High Frequency Selector Switch 1 High Frequency Selector Switch Panel − provides HF without the need for a remote st
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4-4. High Frequency Intensity Control 1 High Frequency Intensity Control 1 Use control to change amount of HF energy used to start and/or maintain the arc. Set as low as practical to prevent interfering with electronic equipment. 4-5. Power Switch And Pilot Light 1 Power Switch Use switch to turn unit On and Off. 2 Pilot Light 1 2 4-6. Postflow Timer Postflow Timer A fixed 15 second Postflow Timer t controls the period of time shielding 2 gas flows after the arc is extin- guished. 4-7. Shielding
