Soft Start
Processes
Description
TIG (GTAW) Welding
OM-189 112
January 1998
Eff. w/Serial Number ME144734
2-2F
1
Stick (SMAW) Welding
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www.MillerWelds.com
Page 1: ...Soft Start Processes Description TIG GTAW Welding OM 189 112 January 1998 Eff w Serial Number ME144734 2 2F 1 Stick SMAW Welding Visit our website at www MillerWelds com ...
Page 2: ...ducts 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 can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The par...
Page 3: ...s Connections 6 3 4 Installing Mounting Brackets Optional 7 3 5 Installing Gas Supply 8 3 6 Remote 14 Receptacle Information and Connections 9 3 7 Remote 14 Plug Information and Connections 9 3 8 Connecting to Weld Input and Output Receptacles 10 3 9 Connecting Input Power 11 SECTION 4 OPERATION 13 4 1 Controls 13 4 2 Safety Equipment 13 4 3 Work Clamp 14 4 4 Shielding Gas 14 4 5 Sequence of Gas T...
Page 4: ...sicurezza per apparecchi di saldatura ad arco Sezione 1 EN 60974 1 1990 Arc Welding Equipment Part 1 Welding Power Sources IEC 974 1 April 1995 Draft revision Apparecchi di saldatura ad arco Sezione 1 Alimentatori per saldatura IEC 974 1 Aprile 1995 Revisione preliminare Degrees of Protection provided by Enclosures IP code IEC 529 1989 Grado di protezione fornito dagli involucri codice IP IEC 529 ...
Page 5: ...or 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 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 D Do n...
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 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 sla...
Page 7: ... maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area i...
Page 8: ... is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one s...
Page 9: ...ct Current U0 Rated No Load Voltage Average U1 Primary Voltage U2 Conventional Load Voltage Line Connection I1 Primary Current I2 Rated Welding Current X Duty Cycle Three Phase Transformer Rectifier IP Degree Of Protection Three Phase S1 KVA Work Connection Wire Feeder Electrode Connection SECTION 3 INSTALLATION 3 1 Specifications Model Drawing Code Rated out Dimensions mm Weight Number 115 V 220 ...
Page 10: ... welding Y Exceeding duty cycle can damage unit and void warranty Overheating 6 Minutes Welding 4 Minutes Resting 0 15 A OR Reduce Duty Cycle Minutes duty1 4 95 Ref SA 168 919 Example 60 Duty Cycle Model 2F Model 1 2 20 25 35 30 40 50 60 70 80 90 100 100 150 200 250 300 3 3 Typical Process Connections Work GTAW Remote foot or hand control Gas out Power cord Gas in To welding power source weld outp...
Page 11: ...for input power make input power connections according to Section 3 9B before installing mounting brackets NOTE 1 Maxstar Welding Power Source Position on top of high frequency unit 2 High FrequencyUnit 3 Notched Mounting Bracket Position notched bracket on right side of units so holes align and ins tall screws Position remaining bracket on left side of units and install with remain ing screws 1 3...
Page 12: ...e 3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Gas Hose Connection 6 Flow Adjust Typical flow rate is 15 cfh cubic feet per hour Make sure flow adjust is closed when opening cylinder to avoid damage to the flowmeter 7 Gas Input Line 8 Gas Out Fitting Connect hose from shielding gas supply regulator flowmeter to Gas In fitting Connect shielding gas hose from torch to Gas Out fitti...
Page 13: ...and signal from remote control Socket Information The remaining sockets are not used Socket AMPERAGE A 3 7 Remote 14 Plug Information and Connections 1 Remote 14 Plug PLG3 2 Keyway To connect plug to a Remote 14 re ceptacle on the welding power source align keyway insert plug and tighten threaded collar 1 A J B K I C L N H D M G E F 2 To Remote 14 Plug on Welding Power Source A 15 volts dc input f...
Page 14: ...Input Plug Red Mark Connect positive input plug to positive weld output receptacle on welding power source GTAW DC Electrode Negative Straight Polarity DCEN 3 Torch Receptacle Connect torch cable 4 Work Receptacle Connect one end of work cable connect remaining end to work piece S 0841 SA 132 499 A ST 800 293 Ref SC 158 511 Input Receptacle Connections Output Receptacle Connections 1 2 4 3 ...
Page 15: ...2 Page 11 3 9 Connecting Input Power A 115 or 230 VAC Input Power Cord Connections GND PE Be sure that the Soft Start is a 230 VAC model Internal connections cannot be made to a Maxstar 175 for input power NOTE ...
Page 16: ...route RC11 through bushing in welding power source case bottom Connect plug PLG11 to receptacle RC11 Use cable ties to secure leads to lead bundle in welding power source so leads are away from fan blade Reinstall welding power source wrapper Install mounting brackets accord ing to Section 3 4 Parts needed for this procedure are supplied with the high frequency unit Tools Needed 1 4 5 2 3 B Power ...
Page 17: ...eld process 5 Amperage Control 6 Upslope Time 0 15 seconds 7 Downslope Time 0 15 sec onds 8 Remote Control Receptacle 9 Gas Outlet 10 Negative Output Terminal 11 Positive Output Terminal 12 Optional Pulser Module 13 Pulser On Off Switch 14 Background Current Adjust ment 15 Pulser Frequency 5 20 Hz or 10 300 Hz Define by switch mark 10 and 300 located on the pulser printed circuit board 16 on Time ...
Page 18: ...before welding Torch output control or foot control turns weld output and gas flow on and off The postflow timne is preset for 10 seconds See circuit diagram fo rthe location of an adjustment potie meter on PC1 Close valve on cylinder when fin ished welding sb5 2 5 94 S 0621 C S 0769 2 1 3 4 OR 4 5 Sequence of Gas Tungsten Arc Welding GTAW Turn On Shielding Gas ssb8 1 12 92 Install Connect Equipme...
Page 19: ...e selected Use correct size or type of tungsten electrode High frequency printed circuit or PC1 is faulty Replace or contact authorized distributor Difficulty in the control of arc or stability Diameter or type of tungsten electrode incorrect Use correct tungsten electrode Worn or faulty remote controls Check for loose connections and worn parts Tungsten electrode oxidizing and not Contact with fi...
Page 20: ...OM 189 112 Page 16 SECTION 6 ELECTRICAL DIAGRAMS PG11 or Power Cord ...
Page 21: ... 0 0 13 1 1 10 116006099 OP 0 0 4 1 11 P C B 028061036 OM 1 1 1 1 12 CR 056057104 DV 11 0 4 1 1 1 13 V 220 057094018 OM 0 5 1 1 13 V 115 057014046 OM 0 6 1 1 13 V 220 057014046 OM 0 6 1 14 Mt 3 200 650020117 1 1 1 15 056076151 DD 0 0 6 2 2 2 16 Cable 027112017 OM 0 2 1 1 16 Cable 027112029 OM 0 8 1 17 Cable 027112018 OM 0 3 1 1 17 Cable 027112030 OM 0 9 1 18 PL 056076172 CZ 0 5 1 1 1 1 19 05609103...
Page 22: ...M 0 0 2 1 1 956142083 OM 0 0 18 1 1 2 000097922 BP 2 0 20 4 4 4 2 Knob 000097922 BP 2 0 20 3 3 Pulser 3 S2 S3 056067169 OM 0 0 6 2 2 2 4 S1 056067168 OM 0 0 5 1 1 1 5 RC 057084050 OM 0 12 1 1 1 6 556049150 DZ 11 0 3 1 1 1 7 50mmq 056076152 DD 0 0 7 2 2 2 8 656110001 EL 0 0 2 4 4 4 9 Pulser Opt 058066006 1 1 10 S4 Pulser 056067021 DZ 12 0 7 1 1 11 Pot 056059182 DC 0 0 9 1 1 Back Gr 12 Pot 056059213...
Page 23: ...covered by the manufacturer s warranty if any 2 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable a...
Page 24: ...ne 414 735 4505 USA Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 Miller Europe Italy Phone 39 0 2982901 Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address Please complete and retain with your personal records Owner s Record ...
