Professional Documents
Culture Documents
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
ENGLISH
OM-225 389U
Syncrowave 200
R
www.MillerWelds.com
ESPAOL
FRANAIS
Description
Mil_Thank 200909
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Included with Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Duty Cycle Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. DC Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. AC Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. 115 Volts AC Duplex Receptacle And Supplementary Protector CB1 . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. Typical TIG Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14. Typical Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16. Connecting Input Power In 208-230 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-17. Connecting Input Power In 460/575 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Ammeter, Voltmeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Amperage/Purge Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Pulse Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Pulser Peak And Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Postflow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Selecting Syncro Start Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Software Number/Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Factory-Set Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING . . . . . . . . . . . . . .
7-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . .
7-2. Preparing Tungsten Electrode For Welding With Phase Control Machines . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
6
6
6
7
7
8
9
9
10
10
11
12
12
13
13
15
15
16
16
16
17
18
19
20
21
22
23
24
25
25
25
26
27
28
30
30
30
31
32
32
32
TABLE OF CONTENTS
SECTION 8 GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
33
33
34
35
36
44
Protect yourself and others from injury read and follow these precautions.
D 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.
D When making input connections, attach proper grounding conductor first double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
READ INSTRUCTIONS.
D Read and follow all labels and the Owners
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owners
Manuals, industry standards, and national, state, and local
codes.
D
D
D
D
D
D
D
D
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
4
5
6
7
8
9
4
6
9
3
804 464-B
Lifting Eye
Lifting Forks
3
OR
2
!
18 in. (460 mm)
18 in.
(460 mm)
ENGLISH
SECTION 2 INSTALLATION
Dimensions
D
Height
Width
Length
Front
804 239-B
Weight
228-1/2 lbs (104 kg)
244-1/2 lbs (111 kg)*
* TIGRunner models
2-5. Specifications
Model
208-230
460
575
Mode
Welding
Rated Input,
60 HZ, Single-Phase
KVA
KW
Amperage Range
Max. OCV
DC TIG
208230 V - 45 A - (2)*
10.2 - (0.50)*
4.3 - (0.3)*
5200
80
DC Stick
208-230 V - 47 A - (2)*
10.8 - (0.50)*
5.8 - (0.3)*
5200
80
AC TIG**
208-230 V - 54 A - (2)*
12.3 - (0.50)*
4.5 - (0.3)*
5200
80
AC Stick
208-230 V - 54 A - (2)*
12.4 - (0.50)*
6 - (0.3)*
5200
80
DC TIG
460 V - 22 A - (1)*
10.2 - (0.50)*
4.3 - (0.3)*
5200
80
DC Stick
460 V - 25 A - (1)*
10.8 - (0.50)*
5.8 - (0.3)*
5200
80
AC TIG**
460 V - 28 A - (1)*
12.3 - (0.50)*
4.5 - (0.3)*
5200
80
AC Stick
460 V - 28 A - (1)*
12.4 - (0.50)*
6 - (0.3)*
5200
80
DC TIG
575 V - 19 A - (.5)*
10.2 - (0.50)*
4.3 - (0.3)*
5200
80
DC Stick
575 V - 20 A - (.5)*
10.8 - (0.50)*
5.8 - (0.3)*
5200
80
AC TIG**
575 V - 22 A - (.5)*
12.3 - (0.50)*
4.5 - (0.3)*
5200
80
AC Stick
575 V - 22 A - (.5)*
12.4 - (0.50)*
6 - (0.3)*
5200
80
* () While idling.
** Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
OM-225 389 Page 6
4 Minutes Welding
6 Minutes Resting
226 798-A
70
60
50
40
30
20
DC Stick Max (Max DIG)
10
0
DC TIG Min
50
DC TIG Max
100
150
AMPS
200
250
300
ssb1.1 10/91 226 800-A
ENGLISH
AC TIG Min
60
50
AC Stick Max
40
30
AC Stick Min
20
10
AC TIG Max
50
100
AMPS
Notes
150
200
ssb1.1 10/91 226 799-A
NOTICE The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
Work
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
10 60%
Duty
Cycle
60 100%
Duty
Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
Welding
Amperes
Electrode
150 ft
(45 m)
804 234-C
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)
Ref. S-0007-G 200908
A
B
H
C L N
D M
G
E F
Socket Information
15 volts DC.
Chassis common.
ENGLISH
2
1
804 267-C
4
Tools Needed:
5/8, 1-1/8 in.
Fitting has
threads.
5/8-18
right-hand
Cylinder Valve
Regulator/Flow Gauge
Flow Adjust
1
2
2
3
Torch
Work Clamp
Cylinder
Cylinder Valve
Regulator/Flow Gauge
Flow Adjust
Tools Needed:
5/8, 1-1/8 in.
ENGLISH
1
2
Electrode Holder
Work Clamp
. Input amperage may be higher than shown in table when Balance control is in an unbalanced position.
. All values calculated at 40% duty cycle.
. Actual input voltage cannot exceed 10% of indicated required input voltage shown in table. If actual input voltage is outside of this range, damage
to unit may occur.
460
575
54
28
22
Time-Delay 2
60
30
25
Normal Operating 3
80
40
30
12
14
147 (45)
249 (76)
256 (78)
12
14
Input Voltage
Input Amperes At Rated Output
Max Recommended Standard Fuse or circuit breaker Rating In Amperes 1
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 Time-Delay fuses are UL class RK5. See UL 248.
3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amps), and UL class H ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Reference: 2005 National Electrical Code (NEC)
OM-225 389 Page 12
7
4
2
6
L1
L2
3
4
5
Over-Current Protection
1
2
Tools Needed:
3/8 in.
Ref. 804 470-B
ENGLISH
9
L1
L2
5
6
2
1
Tools Needed:
3/8 in.
804 470-B
Strain Relief
10 Overcurrent Protection
Close and secure door on line disconnect device. Remove lockout/tagout device, and
place switch in the On position.
ENGLISH
SECTION 3 OPERATION
3-1. Controls
0000
0000
Power Switch
Ammeter
Voltmeter
200 A
Purge Control:
Process Control
!
1
1
2
3
4
Ammeter
Voltmeter
Encoder Adjustment Control
Adjust Control
AC TIG
Display
DC Stick
Display
BAL
DIG
30%
Setting
Typical Starting Point
BAL
More Penetration
BAL
10
43% Electrode
Positive
57% Electrode
Negative
40% Electrode
Positive
60% Electrode
Negative
Arc
ENGLISH
Ammeter
Voltmeter
Encoder Adjustment Control
Pulse Control
PPS
10.0
1
2
3
4
3
0000
Power Switch
Pulse Control
0000
2
Encoder Control
Volt And Ammeter
Press Pulse button to cycle parameters (see Section 3-12 for parameter
ranges).
PPS (Pulses Per Second or Pulse
Frequency) is used to determine appearance of weld bead (See Section
3-6).
PEAK t [PKT] [50%]- The percentage
of each pulse cycle that can be spent
at the peak amperage level.
BKGND A [BKA] [50%] - (Background
Amps) - Use Background Amps to
set the low pulse of the weld amperage, which cools the weld puddle and
affects overall heat input. Background Amps is set as a percentage
of peak amperage.
(50%)
More Time
At Peak
Amperage
(80%)
More Time
At
Background
Amperage
Application:
Pulsed TIG welding involves switching the weld output between a high or
peak amperage, and a low or background amperage at a controlled rate
(see Section 3-6). The raised portions of the weld output are controlled
in width, height, and frequency, forming pulses of weld output. These
pulses and the lower amperage level
between them (called the background amperage) alternately heat
and cool the molten weld puddle. The
combined effect gives the operator
better control of penetration, bead
width, crowning, undercutting, and
heat input. Controls can be adjusted
while welding.
Pulsing can also be used for filler material addition technique training.
(20%)
ENGLISH
0000
0000
1
2
3
Power Switch
Process Control
Encoder Adjust Control
1
2
3
4
0000
0000
Power Switch
Main Amps Control
Volt And Ammeters
Process Selector Switch
To change TIG HF Syncro starting characteristics, turn Off power, place Output
Selector switch in desired position,
DCEN, DCEP or AC. Each position has
three start characteristics options. Push
and hold Main Amps button and turn on
power. Hold button for approximately 7
seconds.
2
Application:
Soft start - use for thin gauge material
and
small
diameter
tungstens
(.0401/16 in)
Medium start - factory-set default, used
for most welding applications with a 1/16,
3/32 or 1/8 in. tungsten.
Hot start - use for thick materials with a
large diameter tungsten (1/85/32 in.).
ENGLISH
0000
0000
1234 Hour
59 MINS
5
1234
5678
Power Switch
Process Control
Pulse Control
Timer Display
ENGLISH
0000
161
221
0000
2
5
REV.A
1
1
2
3
Power Switch
Process Control
Adjust Control
seconds.
5
Revision Display
Default
PROCESS
TIG HF
AC
150 A
5 200 Amps
DC
150 A
5 200 Amps
PULSER
Off
ON / OFF
PPS
10 PPS
0.115 PPS
PEAK t
50%
20 80 Percent
BKGND A
50%
5 95 Percent
POSTFLOW
Auto
5 - 50 Amps: 5 Seconds
A MAIN / PEAK
1 -25 Seconds
DIG
30%
0 100 Percent
BALANCE
110
AC
Med
Soft/Med/Hot
DC
Med
Soft/Med/Hot
Notes
6 Months
Or
Tools Needed:
3
3/8 in.
Spark Gap
Adjustment Screws
ENGLISH
Help 4 Display
HELP
HELP
HELP
OVER
TEMP
XFMR
5
HELP
OVER
TEMP
RECT
8
HELP
REL
RMT
POL
ERR
NOT
VALID
10
Toggles Every
Two Seconds
Toggles Every
Two Seconds
The remedies listed below are recommendations only. If these remedies do not fix the
trouble with your unit, have a Factory Authorized Service Agent check unit.
There are no user serviceable parts inside unit.
Refer to Section 4-3 for any Help (HLP) message displayed on voltmeter/ammeter.
Trouble
No weld output; unit completely
inoperative.
Remedy
Place machine power switch in On position (see Section 3-1).
Place line disconnect switch in On position (see Section 2-16).
Check and replace line fuse(s), if necessary (see Section 2-16).
Check for proper input power connections (see Section 2-16).
Use proper size and type of weld cable (see Section 2-9).
Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.
Be sure Output Selector switch is not set between positions (see Section 3-1).
Tighten remote control connection to Remote 14 receptacle (see Section 2-10).
Check remote control (see remote control Owners Manual).
Unit overheated. Allow unit to cool (see Section 2-6).
ENGLISH
4-4. Troubleshooting
231 276-B
ENGLISH
Figure 5-2. Circuit Diagram For 460/575 Volt Models
231 299-B
High-Frequency Voltage
1
Work
TIG
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Best Practices
Not Followed
S-0694
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece if
required by
codes.
11
10
Ref. S-0695 / Ref. S-0695
Grounding Rod
Whenever possible and practical, use DC weld output instead of AC weld output.
7-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
Amperage Range - Gas Type - Polarity
Electrode Diameter
(DCEN) Argon
AC Argon
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens
.040 (1 mm)
25-85
20-80
50-160
50-150
130-250
135-235
250-400
225-360
10-60
50-100
100-160
150-210
Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
7-2. Preparing Tungsten Electrode For Welding With Phase Control Machines
!
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
Radial Grinding
Causes Wandering Arc
1
3
Grinding Wheel
Tungsten Electrode
Flat
Straight Ground
Tungsten Electrode
Balled End
200704
Grinding the tungsten electrode produces dust and flying sparks which can cause
injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using cerium or
lanthanum based tungsten
instead of thoriated. Thorium dust contains low-level
radioactive material. Properly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
Workpiece
3
2
90
1
Work Clamp
1015
4
5
6
1025
3
4
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
tungsten
Guidelines:
5
1/16 in
3/16 in
Bottom View Of Gas Cup
ENGLISH
Welding direction
Form pool
Tilt torch
Welding direction
Form pool
Tilt torch
Remove rod
15
ST-162 002-B
ENGLISH
90
Butt Weld And Stringer Bead
70
20
20
T Joint
70
10
20
40
Lap Joint
70
20
30
90
Corner Joint
70
20
9-1.
Equipment Needed:
Tools Needed:
Work Clamp
Electrode
5
4
Slag
6
1
6013
7014
7018
7024
Ni-Cl
308L
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
MED
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
EP
6011
AC
PENETRATION
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
DC*
6010
ELECTRODE
450
400
350
300
250
200
150
POSITION
6010
&
6011
100
50
DIAMETER
AMPERAGE
RANGE
ELECTRODE
9-2.
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
9-3.
Striking an Arc
1
2
3
Electrode
Workpiece
Arc
Scratch Technique
3
1
2
3
S-0049 / S-0050
9-4.
1
10-30
90
90
Groove Welds
10-30
45
45
Fillet Welds
S-0060
9-5.
4
2
S-0053-A
9-6.
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
4
5
No Overlap
Good Penetration into Base
Metal
1
S-0052-B
9-7.
by
electrode angle,
arc
length, travel speed, and thickness of base metal.
Correct Angle
10 - 30
Electrode Angle
Drag
Spatter
Arc Length
Too Short
Normal
Too Long
Slow
Normal
Fast
Travel Speed
S-0061
9-8.
. Normally,
1
2
3
a single stringer
bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple
stringer beads work better.
Stringer Bead Steady
Movement Along Seam
Weave Bead Side to Side
Movement Along Seam
Weave Patterns
S-0054-A
9-9.
Tack Welds
1/16 in.
(1.6 mm)
30
S-0062
Electrode
Single-Layer Fillet Weld
30
Or Less
30
Or Less
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
S-0063 / S-0064
Electrode
Fillet Weld
Keep arc short and move at definite rate of speed. Hold electrode
as shown to provide fusion into the
corner. Square edge of the weld
surface.
For maximum strength weld both
sides of upright section.
45
Or
Less
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
9-8. Remove slag before making
another weld pass.
Vise
Weld Joint
Hammer
3
3
2 To 3 in.
(51-76 mm)
1/4 in.
(6.4 mm)
2
1
2 To 3 in.
(51-76 mm)
2
1
S-0057-B
9-13. Troubleshooting
Porosity small cavities or holes resulting from gas pockets in weld metal.
Possible Causes
Corrective Actions
Damp electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
OM-225 389 Page 41
Lack Of Penetration shallow fusion between weld metal and base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Material too thick. Joint preparation and design must provide access to bottom of groove.
Corrective Actions
Possible Causes
Corrective Actions
Possible Causes
Corrective Actions
Unsteady hand.
Corrective Actions
Notes
34
32
68
67
46
65
44
43
45
63
49
55
50
53
1
9
8
56
52
58
14
17
21
70
59
12
18
13
51
61
11
57
16
22
20
69
15
24
25
48
39
42
40
64
25
26
71
23
66
47
60
38
28
41
37
30
29
31
19
62
27
33
805 461-C
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
2
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
1
1
1
1
2
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
13
3
4
5
6
3
10
8
12
9
803 775-B
11
Dia.
Mkgs.
Part
No.
Description
223 981
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
213 109
218 174
185 717
229 338
185 713
224 529
185 718
185 712
186 228
202 811
202 553
218 784
185 706
..
..
..
..
..
..
..
..
..
..
..
..
..
Quantity
10-2. Panel, Lower Dinse Connector Assy (Figure 10-1 Item 56)
PANEL, LOWER DINSE CONN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, W/LEADS & CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . .
NUT, M201.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, DOMED LOAD .812 ID X 1.450 OD X .070 THK . . . . . . . . . . . . . .
INSULATOR, BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN, CIRC MS/CPC 14SKT SIZE 20 RCPT W/FILTERING . . . . . . . . . . . . .
ORING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE,TWIST LOCK ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, TWIST LOCK BRASS POWER (FEMALE) . . . . . . . . . . . . . . .
LABEL, COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LNUT, M121.0 .62HEX .24H BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
2
1
2
2
2
1
1
1
1
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-225 389 Page 47
3
2
4
804 399-A
Dia.
Mkgs.
Part
No.
Description
224 496
...
...
...
...
1
2
3
4
..........
..........
..........
..........
206 984
206 327
224 488
208 384
..
..
..
..
Quantity
1
1
2
2
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.
Notes
Notes
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also 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.
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 6. 90 Days Parts
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
* Accessory (Kits)
original retail purchaser that new Miller equipment sold after the
* Canvas Covers
effective date of this limited warranty is free of defects in material
* Induction Heating Coils and Blankets, Cables, and
and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* M-Guns
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* MIG Guns and Subarc (SAW) Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
* Replacement Parts (No labor)
any warranted parts or components that fail due to such defects in
* Roughneck Guns
material or workmanship. Miller must be notified in writing within
* Spoolmate Spoolguns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed.
1.
2.
3.
4.
5.
1.
2.
3.
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
201101