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OM-189 116 Page 12

SECTION 5 – ELECTRICAL DIAGRAMS

GND

PCB1

R

S

230V

S1

FM

1

PCB2

J5-J6

J7

J7

J3-J4

J8

BSI

BS2

J2

10

1

PCB3

SH1

J2

J1

XL

T1

J1

J2

J3

J4

J1

J2

RC1

A

B

D

E

C

PCB4

J4

6

5

4

3

2

1

J4

J5

11

8

1

40

PCB6

J2

J1

12

3
4
5

778

1
2
3
4

5
6

6

Gs

RC1

PCB5

DL1

DL2

DL3

SWR1

Arc Weld

T

ig 4T

T

ig 2T

Res. T

ig

Spot W

.

654

3
2

1

On

W

eld.

Overtemp.

R5

R6

R7

WORK

ELECTRODE

+

–

230V

9V

18V

24V

00

0

0

T2

J4

S2

S3

Std/Rmt

Lift

I

1

-I

2

I We
ld

.

Pos

t

Gas

S-142 310

Figure 5-1. Circuit Diagram For 230 Volt Input Models

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Summary of Contents for Gold Seal 160 i

Page 1: ...160 i Processes Description TIG GTAW Welding Stick SMAW Welding Arc Welding Power Source OM 189 116A June 1999 Effective with Serial N 230 Volt 159 262 240 Volt 160 261 Visit our website at www Miller...

Page 2: ...ucts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you...

Page 3: ...Connections 7 2 7 Weld Output Terminals And Selecting Cable Sizes 8 2 8 Electrical Service Guide 8 2 9 Connecting Input Power 9 SECTION 3 OPERATION 10 3 1 Controls 10 SECTION 4 MAINTENANCE AND TROUBLE...

Page 4: ...ibility Directives 89 336 EEC Low Voltage 73 23 EEC Machinery Directives 89 392 EEC And their amendments 91 368 EEC 93 31 EEC 93 44 EEC 93 68 EEC Standards Electromagnetic compatibility EMC Product st...

Page 5: ...r 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 powe...

Page 6: ...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 lig...

Page 7: ...ury 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...

Page 8: ...one 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...

Page 9: ...4 in 270 mm Width 9 1 8 in 230 mm Length 15 3 4 in 400 mm 2 2 Duty Cycle And Overheating 6 Minutes Welding 4 Minutes Resting Duty Cycle is percentage of 10 min utes that unit can weld at rated load w...

Page 10: ...f unit 802 276 2 4 Selecting A Location 1 Rating Label Use rating label to determine input power needs 2 Line Disconnect Device Locate unit near correct input pow er supply Y Special installation may...

Page 11: ...OM 189 116 Page 7 2 5 Typical Connections A Typical Stick SMAW Connections B Typical TIG GTAW Connections 2 6 Front Panel Connections Gas Hose Connector Remote Contactor And Current Control Receptacle...

Page 12: ...100 Duty Cycle 10 100 Duty Cycle 100 4 4 4 3 2 1 1 0 1 0 150 3 3 2 1 1 0 2 0 3 0 3 0 200 3 2 1 1 0 2 0 3 0 4 0 4 0 Negative Positive 250 2 1 1 0 2 0 3 0 4 0 2 2 0 2 2 0 Weld cable size AWG is based o...

Page 13: ...e 9 2 9 Connecting Input Power 1 Rating Label Supply correct input power See Section 2 8 2 Line Disconnect Device Check input voltage available at site 2 1 1 L1 L2 Y Always connect grounding conductor...

Page 14: ...or Electrode 2T 4T Spot Welding Repeat Cycle 6 0 5 4 2T 4T t 4 1 8 t 1 0 3 2 35 4 5 5 5 s 6 10 20 3 220 300Hz 130 50 A t 20 35 12 s 8 80 90 5 3 65 50 18 20 15 20 5 40 50 70 80 100 110 130 145 160 1 7...

Page 15: ...and output connections see Sections 2 7 and or 2 9 Erratic or improper weld output Tighten all welding cable connections see Sections 2 7 Check for proper size and type of cable see Section 2 7 Check...

Page 16: ...1 J2 RC1 A B D E C PCB4 J4 6 5 4 3 2 1 J4 J5 1 18 1 40 PCB6 J2 J1 1 2 3 4 5 7 7 8 1 2 3 4 5 6 6 Gs RC1 PCB5 DL1 DL2 DL3 SWR1 Arc Weld Tig 4T Tig 2T Res Tig Spot W 6 5 4 3 2 1 On Weld Overtemp R5 R6 R7...

Page 17: ...E C PCB4 J4 6 5 4 3 2 1 J4 J5 1 18 1 40 PCB6 J2 J1 1 2 3 4 5 7 7 8 1 2 3 4 5 6 6 Gs RC1 PCB5 DL1 DL2 DL3 SWR1 Arc Weld Tig 4T Tig 2T Res Tig Spot W 6 5 4 3 2 1 On Weld Overtemp R5 R6 R7 WORK ELECTRODE...

Page 18: ...are 15 to 35 cfh cubic feet per hour 7 to 16 5 lpm liters per minute Not Recommended The figures listed are intended as a guide and are a composite of recommendations from American Welding Society AWS...

Page 19: ...re weld ing Do not use wheel for other jobs or tungsten can become contami nated causing lower weld quality 3 Ideal Tungsten Preparation Stable Arc 2 1 2 Times Electrode Diameter 1 2 1 Stable Arc 2 Fl...

Page 20: ...way 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tun...

Page 21: ...002 B Tungsten Without Filler Rod Tungsten With Filler Rod Form pool Tilt torch Move torch to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to f...

Page 22: ...OM 189 116 Page 18 7 3 Positioning Torch Tungsten For Various Weld Joints ST 162 003 S 0792 70 70 90 20 20 10 20 70 40 30 20 70 90 20 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint...

Page 23: ...OM 189 116 Page 19 Notes...

Page 24: ...189 116 Page 20 SECTION 8 PARTS LIST Hardware is common and not available unless listed 3 1 4 5 7 9 8 10 32 11 31 12 14 15 16 14 19 17 18 30 21 22 23 25 20 24 26 28 13 6 2 29 27 Figure 8 1 Main Assemb...

Page 25: ...9 2 15 556049361 VG 0 0 20 1 16 056076170 FS 1 0 3 1 RC1 17 156006012 VG 0 0 21 1 18 057084075 VG 0 5 1 Sec P C B 3 V 230 18 057084078 VG 0 9 1 Sec P C B 3 V 240 19 057014097 VG 0 6 1 20 056159012 VG...

Page 26: ...Notes...

Page 27: ...ings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if...

Page 28: ...linois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA Phone 920 735 4505 USA Canada FAX 920 735 4134 International FAX 920 735 4125 Model Name Serial...

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