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OM-2231 Page 2

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.

ARC RAYS can burn eyes and skin.

D

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).

D

Wear approved safety glasses with side shields under your
helmet.

D

Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.

D

Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.

WELDING can cause fire or explosion.

D

Protect yourself and others from flying sparks and hot metal.

D

Do not weld where flying sparks can strike flammable material.

D

Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.

D

Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.

D

Watch for fire, and keep a fire extinguisher nearby.

D

Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.

D

Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).

D

Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.

D

Do not use welder to thaw frozen pipes.

D

Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.

D

Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.

D

Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.

FLYING METAL can injure eyes.

D

Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.

D

Wear approved safety glasses with side
shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D

Shut off shielding gas supply when not in use.

D

Always ventilate confined spaces or use
approved air-supplied respirator.

HOT PARTS can cause severe burns.

D

Do not touch hot parts bare handed.

D

Allow cooling period before working on gun or
torch.

MAGNETIC FIELDS

 can affect pacemakers.

D

Pacemaker wearers keep away.

D

Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D

Wear approved ear protection if noise level is
high.

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.

CYLINDERS can explode if damaged.

D

Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.

D

Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.

D

Keep cylinders away from any welding or other electrical circuits.

D

Never drape a welding torch over a gas cylinder.

D

Never allow a welding electrode to touch any cylinder.

D

Never weld on a pressurized cylinder − explosion will result.

D

Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.

D

Turn face away from valve outlet when opening cylinder valve.

D

Keep protective cap in place over valve except when cylinder is in
use or connected for use.

D

Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.

Summary of Contents for ALT 304

Page 1: ...Visit our website at www MillerWelds com Processes Description Multiprocess Welding Arc Welding Power Source OM 2231 198 248J August 2003 ALT 304...

Page 2: ...ue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the...

Page 3: ...ION 3 INSTALLATION 11 3 1 Selecting a Location 11 3 2 Weld Output Receptacles And Selecting Cable Sizes 12 3 3 Remote 14 Receptacle Information 12 3 4 Optional Gas Valve Operation And Shielding Gas Co...

Page 4: ......

Page 5: ...that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conduc tor first double check connections D Frequently inspect input power...

Page 6: ...lding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane light...

Page 7: ...y D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference D High frequency H F can interfere with radio n...

Page 8: ...e 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Su...

Page 9: ...tation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre D En effectuant les raccordements d entr e fixer d abord le conduc...

Page 10: ...r des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef D Avant de souder retirer to...

Page 11: ...vrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences D Le rayonnement haute frequence peut provoquer des interf rences avec les quipements de...

Page 12: ...nd Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 webs...

Page 13: ...age Range in CV Mode Range in CC Mode Circuit Voltage 208 V 230 V 460 V 575 V KVA KW 3 Phase 300 A at 32 VDC 10 35 V 5 400 A 85 VDC 33 27 30 14 79 11 72 12 11 5 1 Phase 225 A at 29 VDC 41 2 37 3 15 5...

Page 14: ...d load without overheating If unit overheats output stops a Help message is displayed and cooling fan runs Wait fifteen min utes for unit to cool Reduce amper age or voltage or duty cycle before weldi...

Page 15: ...ormation on rear panel to determine input power needs 4 Line Disconnect Device Locate unit near correct input power supply Y Special installation may be required where gasoline or volatile liquids are...

Page 16: ...4 volts or less drop or a current density of at least 300 circular mils per ampere S 0007 D 3 3 Remote 14 Receptacle Information Socket Socket Information 24 VOLTS AC A 24 volts ac Protected by circui...

Page 17: ...e Shielding and Hose Coupler Brass Connect hose coupler to torch Connect one end of gas hose to hose coupler Connect remaining end of gas hose to Gas Out fitting Operation The gas solenoid controls ga...

Page 18: ...on to reset breaker 2 3 1 3 5 Optional 115 Volts AC Duplex Receptacle And Circuit Breakers 3 6 Electrical Service Guide Single Phase Input Voltage 208 230 460 Input Amperes At Rated Output 41 2 37 3 1...

Page 19: ...5 VAC 1 Input And Grounding Conductors 2 Line Disconnect Device See Section 3 6 For single phase operation 3 Black And White Input Conductor 4 Red Input Conductor 5 Insulation Sleeving 6 Electrical Ta...

Page 20: ...h in Re mote position In most modes remote con trol is a percent of V A Adjust control setting value selected on V A Adjust is maximum available on remote In the MIG mode re mote control provides full...

Page 21: ...On Off At Remote 14 Stick SMAW Electrode Hot V Sense Feeder MIG GMAW With Voltage Sensing Wire Feeder Electrode Hot 4 3 Lift Arc TIG Procedure With Process Switch in the Lift Arc TIG position start an...

Page 22: ...hs Replace Damaged Or Unreadable Labels Replace Cracked Torch Body Repair Or Replace Cracked Cables Repair Or Replace Cracked Cables And Cords Clean And Tighten Weld Connections 6 Months Blow Out Insi...

Page 23: ...o weld output unit completely inop erative Place line disconnect switch in On position see Section 3 7 Check and replace line fuse s if necessary or reset circuit breaker see Section 3 7 Check for pro...

Page 24: ...OM 2231 Page 20 SECTION 6 ELECTRICAL DIAGRAM Figure 6 1 Circuit Diagram...

Page 25: ...OM 2231 Page 21 196 695 E...

Page 26: ...1 2 3 4 5 6 7 8 9 12 13 11 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 40 41 44 45 46 47 48 49 52 51 50 12 11 14 53 54 55 56 58 59 61 62 64 63 65 66 67 5...

Page 27: ...Str Dx Grd 2p3w 15A 125V 5 15r 1 18 CB2 083 432 Circuit Breaker Man Reset 1p 10A 250VAC Frict 1 19 CB1 083 432 Circuit Breaker Man Reset 1p 10A 250VAC Frict 1 19 CB1 089 807 Circuit Breaker Man Reset...

Page 28: ...m Dinse Type 50 70 Series wsl 2 61 FM 196 313 Fan Muffin 115V 50 60hz 3000 Rpm 6 378 Mtg Holes 1 62 201 943 Adapter Louver Box 1 63 203 396 Door Front Injection Molded 1 64 175 138 Box Louver 1 65 174...

Page 29: ......

Page 30: ......

Page 31: ...Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzle...

Page 32: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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