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OM-316 Page 2

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D

Keep your head out of the fumes. Do not breathe the fumes.

D

If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended way

to determine adequate ventilation is to sample for the composition

and quantity of fumes and gases to which personnel are exposed.

D

If ventilation is poor, wear an approved air-supplied respirator.

D

Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

D

Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D

Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D

Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

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.

D

Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and

sparks 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,

glare and sparks; warn others not to watch the arc.

D

Wear body protection made from durable, flame

resistant mate-

rial (leather, heavy cotton, wool). Body protection includes

oil-free clothing such as leather gloves, heavy shirt, cuffless

trousers, high shoes, and a cap.

ARC RAYS can burn eyes and skin.

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

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

Do not weld where flying sparks can strike flammable material.

D

Protect yourself and others from flying sparks and hot metal.

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 containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are

properly prepared according to AWS F4.1 and AWS A6.0 (see

Safety Standards).

D

Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

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, sparks, 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 body protection made from durable, flame

resistant material

(leather, heavy cotton, wool). Body protection includes oil-free

clothing 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.

D

After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D

Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

D

Read and understand the Safety Data Sheets (SDSs) and the

manufacturer s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT 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 compressed gas supply when not in use.

D

Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.

D

Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D

Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding,  spot

welding, gouging, plasma arc cutting, or induction heating

operations.

Noise from some processes or equipment can

damage hearing.

D

Wear approved ear protection if noise lev-

el is high.

NOISE can damage hearing.

Compressed 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, physical damage, 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 compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them

and associated parts in good condition.

D

Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D

Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D

Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D

Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

Содержание Thunderbolt XL

Страница 1: ...200 AC DC OM 316 087 083U 2014 02 Visit our website at www MillerWelds com File Stick SMAW Processes Stick SMAW Welding Description Arc Welding Power Source 225 AC Models 225 150 AC DC Models 300 200...

Страница 2: ...ntinue 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...

Страница 3: ...ves aux CEM 9 SECTION 3 DEFINITIONS 11 3 1 Miscellaneous Symbols And Definitions 11 SECTION 4 SPECIFICATIONS 12 4 1 Unit Specifications 12 4 2 Duty Cycle Charts 13 4 3 Volt Ampere Curves 14 SECTION 5...

Страница 4: ......

Страница 5: ...eling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC c...

Страница 6: ...ed according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close...

Страница 7: ...PARTS can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards f...

Страница 8: ...PA 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 Indus try Title 29 Code of...

Страница 9: ...IQUE MENT si le proc d de soudage le demande D Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autre...

Страница 10: ...s et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc D Porter un quipement de protection pour le corps fait d un mat riau r sistant et ignifuge cuir coton robuste laine La...

Страница 11: ...s en bon tat D Tourner le dos la sortie de vanne lors de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gulateur lors de l ouverture de la vanne D Le couvercle du d t...

Страница 12: ...de rechange recommand es par le constructeur D Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QU...

Страница 13: ...Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part...

Страница 14: ...OM 316 Page 10...

Страница 15: ...rnating Current Electrode Positive Electrode Negative Direct Current Welding Arc V Volts Work Electrode Single Phase Transformer Single Phase Transformer AC Rectifier DC Power Source Line Connection I...

Страница 16: ...ycle 50 Hz 30 160 80 VDC AC 300 A 30 Volts AC 20 Duty Cycle 50 60 Hz Low 40 200 High 65 300 80 VAC 70 5 4 134 lbs 61 kg DC 200 A 25 Volts DC 20 Duty Cycle 50 60 Hz 30 200 80 VDC Overall Dimensions Hei...

Страница 17: ...E Exceeding duty cycle can damage unit and void warranty B For 300 200A Models A For 225 150A Models These models have a 15 duty cycle when used with 50 Hz input power 2 Minutes Welding 8 Minutes Rest...

Страница 18: ...s fall be tween the curves shown A For 225 150A Models B For 300 200A Models 0 10 20 30 40 50 60 70 80 90 100 0 100 200 300 400 DC Amperes DC Volts MIN MAX 0 10 20 30 40 50 60 70 80 90 100 0 50 100 15...

Страница 19: ...s 193 508 The volt ampere curves show the minimum and maximum voltage and amperage output capabilities Curves of other settings fall be tween the curves shown For 225A Models 0 10 20 30 40 50 60 70 80...

Страница 20: ...er requirements and or rated output For future reference write serial number in space provided on back cover of this manual 5 2 Selecting A Location 804 292 A 802 105 D Special installation may be req...

Страница 21: ...Electrode Cable and Barrel onto Electrode Holder 5 Electrode Cable From Unit Has Bare Conductors on End 6 Terminal Screw Back out terminal screw from elec trode holder Insert electrode cable through b...

Страница 22: ...5 67 Max Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses2 90 50 80 Normal Operating Fuses 3 110 70 100 Min Input Conductor Size In AWG 4 8 12 10 Max Recommended Input Conductor Length I...

Страница 23: ...L2 For Models Not Supplied With Plug Installationmust meet all National and Local Codes have only qualified per sons make this installation Disconnect and lockout tagout input power before connecting...

Страница 24: ...ntrols For AC DC Models Ref 217 857 B 802 105 D 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch For DC Weld Output Use mode switch to select polarity of dc output Electrode Posi tive DCEP o...

Страница 25: ...s available at www MillerWelds com OM 316 Page 21 B Controls For AC Models Ref 218 237 A 802 105 D 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch Use mode switch to select AC low range or...

Страница 26: ...nt 802 248 D Turn Off welding power source and disconnect input power 1 Wrapper Remove wrapper 2 Shunt Block Do not grease screw threads on shunt block Apply light coating of high tempera ture grease...

Страница 27: ...Pinion Gear Install pinion gear onto front panel making sure anti rotation pins are in holes on front panel 6 Pointer Gear Install pointer gear overtop of pinion gear and rotate so pointer is indicat...

Страница 28: ...ay Be sure nothing is blocking movement of fan If fan does not run freely replace fan motor Erratic weld current Clean and tighten all weld cable connections Erratic arc with excessive spatter Use dry...

Страница 29: ...DIAGRAMS 191 364 Figure 8 1 Circuit Diagram For 225 150 AC DC 230 Volts Models 191 368 220 PRI SEC T1 GRN VOLT ONLY S2 WORK ELECTRODE R Z1 SR1 S O P POWER CORD FM S1 S O P Figure 8 2 Circuit Diagram...

Страница 30: ...OM 316 Page 26 191 362 WORK 230 PRI SEC T1 GRN VOLT ONLY S2 AC HIGH AC LOW ELECTRODE PLG1 FM S1 Figure 8 3 Circuit Diagram For 225 AC 230 Volts Models...

Страница 31: ...s current than a large one Fol low recommendations of the elec trode manufacturer when setting weld amperage see Section 9 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc l...

Страница 32: ...ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER MED...

Страница 33: ...produce the best results hold a short arc travel at a uniform speed and feed the electrode downward at a constant rate as it melts 1 1 2 2 Groove Welds Fillet Welds 9 5 Poor Weld Bead Characteristics...

Страница 34: ...ide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patt...

Страница 35: ...good welds The single or double V groove weld is good for materials 3 16 3 4 in 5 19 mm thick Generally the single V groove is used on ma terials up to 3 4 in 19 mm thick and when regardless of thickn...

Страница 36: ...Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding Excessi...

Страница 37: ...and or maintain steady travel speed Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Sel...

Страница 38: ...Notes...

Страница 39: ...Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Ex...

Страница 40: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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