Professional Documents
Culture Documents
Processes
TIG (GTAW) Welding
Description
)
Syncrowave 210
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
D Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information D When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord and ground conductor for
repair this unit. damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
During operation, keep everybody, especially children, away. D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill.
D If earth grounding of the workpiece is required, ground it directly
Touching live electrical parts can cause fatal shocks with a separate cable.
or severe burns. The electrode and work circuit is D Do not touch electrode if you are in contact with the work, ground,
electrically live whenever the output is on. The input or another electrode from a different machine.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic D Do not touch electrode holders connected to two welding ma-
wire welding, the wire, wire reel, drive roll housing, chines at the same time since double open-circuit voltage will be
and all metal parts touching the welding wire are present.
electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts. D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats D Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground. D Insulate work clamp when not connected to workpiece to prevent
D Do not use AC output in damp areas, if movement is confined, or if contact with any metal object.
there is a danger of falling. D Do not connect more than one electrode or work cable to any
D Use AC output ONLY if required for the welding process. single weld output terminal. Disconnect cable for process not in
use.
D If AC output is required, use remote output control if present on
unit. D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
D Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
SIGNIFICANT DC VOLTAGE exists in inverter weld-
as floors, gratings, or scaffolds; when in cramped positions such ing power sources AFTER removal of input power.
as sitting, kneeling, or lying; or when there is a high risk of unavoid- D Turn Off inverter, disconnect input power, and discharge input
able or accidental contact with the workpiece or ground. For these capacitors according to instructions in Maintenance Section
conditions, use the following equipment in order presented: 1) a before touching any parts.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder HOT PARTS can burn.
is recommended. And, do not work alone!
D Do not touch hot parts bare handed.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to D Allow cooling period before working on
OSHA 29 CFR 1910.147 (see Safety Standards). equipment.
D Properly install, ground, and operate this equipment according to D To handle hot parts, use proper tools and/or wear heavy, insu-
its Owner’s Manual and national, state, and local codes. lated welding gloves and clothing to prevent burns.
OM-261726 Page 1
D Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
D Keep your head out of the fumes. Do not breathe the fumes. D Remove any combustibles, such as a butane lighter or matches,
D If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way D After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator. pass them.
D Read and understand the Safety Data Sheets (SDSs) and the D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. D Read and understand the Safety Data Sheets (SDSs) and the
D Work in a confined space only if it is well ventilated, or while manufacturer’s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
D Do not weld on coated metals, such as galvanized, lead, or D Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and D Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). D Implanted Medical Device wearers should consult their doctor
D Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
D Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
D Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.
OM-261726 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
OM-261726 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
A Amperes
U1 Primary Voltage Output
Protective Earth
(Ground) U0 Rated No Load
Voltage (OCV)
Direct Current (DC)
On
IP Degree Of Protection
Gas Tungsten Arc
Welding (GTAW)
Alternating
Current I1eff Maximum Effective
Supply Current Up Rated Peak
Voltage
Inverter Power
I2 Rated Welding
Current Hz Hertz Source With
AC/DC Output
OM-261726 Page 9
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SECTION 4 − SPECIFICATIONS
4-1. Included with Your Unit
1 12 ft (3.7 m) Work Cable
With Clamp And
5 Quick-Connect
2 WP1712SFDI 150 Amp
TIG Torch with 12 ft (3.7 m)
Cable And Quick-Connect
3 Electrode Holder and
Quick-Connect
4 Gas Hose
4
5 Gas Regulator
6 6 Power Cable Adapter
7 Cable/Torch Hanger
8 Foot Pedal Holder
9 RFCS-14 Foot Control with
20 ft (6 m) Cable
3 . Some assembly is required.
7 For options and accessories see
back of book or contact your dis-
9 tributor.
2
1
805 522-A
Notes
OM-261726 Page 10
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4-3. Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-8, 5-10 and/or 5-11 for information
on connecting input power.
Welding
Input Amperage Amps Input At
Process
Power Range Rated Output Rated Output KVA KW Max. OCV
75 A at 13 V, 100% Duty Cycle 13.2 (.58)* 1.54 (.07)* 1.46 (.02)*
DC TIG 5 − 125 95 A at 13.8 V, 60% Duty Cycle 17.4 (.58)* 2.05 (.07)* 1.94 (.02)*
125 A at 15 V, 35% Duty Cycle 25.2 (.58)* 3.04 (.07)* 2.79 (.02)*
75 A at 13 V, 100% Duty Cycle 10.4 (.58)* 1.20 (.07)* 1.12 (.02)*
115 VAC AC TIG 5 - 114 90 A at 13.6 V, 60% Duty Cycle 12.4 (.58)* 1.43 (.07)* 1.33 (.02)* 47 VDC
114 A at 14.6 V, 35% Duty Cycle 18.3 (.58)* 2.11 (.07)* 1.98 (.02)*
55 A at 22.2 V, 100% Duty Cycle 15.6 (.58)* 1.84 (.07)* 1.74 (.02)*
Stick 20 − 90 70 A at 22.8 V, 60% Duty Cycle 20.5 (.58)* 2.47 (.07)* 2.30 (.02)*
90 A at 23.6 V, 35% Duty Cycle 25.9 (.58)* 3.14 (.07)* 2.87 (.02)*
95 A at 13.8 V, 100% Duty Cycle 8.4 (.35)* 1.96 (.08)* 1.84 (.02)*
5 − 210 125 A at 15 V, 60% Duty Cycle 11.9 (.35)* 2.72 (.08)* 2.61 (.02)*
DC TIG 150 A at 16 V, 40% Duty Cycle 14.7 (.35)* 3.43 (.08)* 3.31 (.02)*
210 A at 18.4 V, 20% Duty Cycle 23.6 (.35)* 5.56 (.08)* 5.35 (.02)*
90 A at 13.6 V, 100% Duty Cycle 6.6 (.35)* 1.53 (.08)* 1.44 (.02)*
230 VAC 114 A at 14.6 V, 60% Duty Cycle 8.62 (.35)* 1.99 (.08)* 1.91 (.02)* 47 VDC
AC TIG 5 - 184 138 A at 15.5 V, 40% Duty Cycle 12.1 (.35)* 2.80 (.08)* 2.69 (.02)*
184 A at 17.4 V, 20% Duty Cycle 16.6 (.35)* 3.84 (.08)* 3.77 (.02)*
60 A at 22.4 V, 100% Duty Cycle 7.9 (.35)* 1.84 (.08)* 1.72 (.02)*
Stick 20 -150 90 A at 23.6 V, 60% Duty Cycle 11.9 (.35)* 2.79 (.08)* 2.68 (.02)*
150 A at 26 V, 20% Duty Cycle 21.8 (.35)* 5.12 (.08)* 4.94 (.02)*
( )* While idling.
Dimensions
C 43 in. (1092)
805 519-A
Weight
OM-261726 Page 11
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Notes
OM-261726 Page 12
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SECTION 5 − INSTALLATION
5-1. Selecting A Location
Movement
! Do not move or operate unit
where it could tip.
18 in. (460
18 in. (460 mm) mm)
OM-261726 Page 13
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A 15 volts DC.
K Chassis common.
Notes
OM-261726 Page 14
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OR
805 521-A
OM-261726 Page 15
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5-5. Removing Power Pin Style Connector To Adapt Spoolmate 100/150 Models For Use
With The Syncrowave 210
5-6. Installing Dinse Style Connector To Adapt Spoolmate 100/150 Models For Use With
The Syncrowave 210
OM-261726 Page 16
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5-7. Adapter Cord Connections To Adapt Spoolmate 100/150 Models For Use With The
Syncrowave 210
! Turn Off welding power
source before connecting
adapter cable.
1 4 To 14-Pin Adapter
2 14-Pin Receptacle
Insert spool gun control cable 4-pin
plug into matching receptacle on
4-pin adapter cord and tighten collar.
Connect 14−pin plug end of adapter
cord to matching 14-pin receptacle
on welding power source and tighten
1
collar.
805 521-A
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
OM-261726 Page 17
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230 471 (144) 321 (98) 215 (66) 146 (45) 90 (27)
1
2
OM-261726 Page 18
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Notes
OM-261726 Page 19
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L1
5
L2
6
L2 L1
230 VAC, 1
Tools Needed:
input4 2012−05 − Ref. 803 766-C / Ref. 805 519-A / Ref. 805 540-A
OM-261726 Page 20
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! Installation must meet all National and See rating label on unit and check input volt- 7 Over-Current Protection
Local Codes − have only qualified per- age available at site.
sons make this installation. Select type and size of over-current protec-
1 Input Power Cord tion using Section 5-8 (fused disconnect
! Disconnect and lockout/tagout input 2 Disconnect Device (switch shown in the switch shown).
power before connecting input con- OFF position)
ductors from unit. Follow established 3 Disconnect Device Grounding Terminal Close and secure door on disconnect device.
procedures regarding the installation Follow established lockout/tagout proced-
4 Disconnect Device Line Terminals ures to put unit in service.
and removal of lockout/tagout
devices. 5 Black And White Input Conductor (L1
And L2) 8 Multi-Voltage Plug And Power Cord
! Always connect green or green/yellow Connector (NEMA 6-50P Plug Shown)
6 Green Or Green/Yellow Grounding
conductor to supply grounding termi- Conductor For multi−voltage plug connections, see Sec-
nal first, and never to a line terminal.
Connect green or green/yellow grounding tion 5-12.
. The Auto-Line circuitry in this unit auto- conductor to disconnect device grounding
terminal first. 9 Receptacle (NEMA 6-50R)
matically links the power source to the (Customer Supplied)
primary voltage being applied, either 115 Connect input conductors L1 and L2 to dis-
or 230 VAC. connect device line terminals. Connect plug to receptacle.
Notes
OM-261726 Page 21
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Selecting Plug
2
1
3
Selecting Plug 4 Plug − NEMA Type 5−20P (Optional Connecting Plug To Power Cord
Part No. 219259)
1 Power Cord Connector From 5 Receptacle − NEMA Type 5−20R
Welding Power Source Align arrow on plug with arrow on power
(Customer Supplied)
cord connector. Push together.
Select plug for power supply receptacle 6 Plug − NEMA Type 6−50P
available at site. Not all plugs shown are 7 Receptacle − NEMA Type 6−50R
provided as standard with unit. (Customer Supplied) Tighten threaded collar. As threaded collar
is tightened, push plug onto adapter until
2 Plug − NEMA Type 5−15P ! Follow electrical service guide for
collar is completely tight.
230 VAC in Section 5-8. Do not use
3 Receptacle − NEMA Type 5−15R plug rating to size branch circuit
(Customer Supplied) protection. Connect plug to receptacle.
OM-261726 Page 22
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SECTION 6 − OPERATION
6-1. Syncrowave 210 Controls
3 4 1
6 7
8
OM-261726 Page 23
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150A
268 890-B
Amperage Control:
PPS OFF crease travel speed. Set PPS (pulses per second).
The range is OFF−50 PPS. The Background Amper-
age and Peak Amperage are not adjustable. Back-
ground Amperage equals 25% of Peak amperage.
Peak amperage Time equals 40%.
*PRO−SET provides PROfessionally de- TIP: AC Balance controls the cleaning TIP: AC Frequency controls the width of
veloped SETtings for the weld process. action. If floating black spots appear in the arc cone. For thin fillet welds (less
To use PRO−SET, press the menu button the puddle, the balance setting is too high. than 1/4 in.) set the frequency to 120 Hz.
to display the parameter and adjust the Turn the balance down until puddle be- This frequency setting provides a focused
encoder until PRO−SET flashes on the comes clear. stable arc and produces a narrow weld.
display. PRO−SET flashes one time and For outside corner or groove welds on
reveals the professional setting for the heavy material, a wide weld may be re-
parameter. quired. Lower the frequency to between
70 and100 Hz. This frequency setting pro-
duces a wider weld.
OM-261726 Page 24
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OM-261726 Page 25
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Notes
OM-261726 Page 26
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USER MENU
268 890-B
OM-261726 Page 27
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USER MENU 1
268 890-B
OM-261726 Page 28
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USER MENU
150A
150A
1
268 890-B
OM-261726 Page 29
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1 Menu Button
Press and hold Menu button for ap-
2 3 4 1 proximately 4 seconds to scroll
past User Menu to Tech Menu. Use
Menu button to cycle through para-
meters that can be set.
2 Parameter Display
3 Setting Display
4 Encoder
Rotate Encoder to adjust paramet-
er setting.
To exit user menu, press and hold
TECH MENU menu button approximately one
second, or turn power off.
268 890-B
ARC T/CY [ARC] [T/CY] Arc Timer: Monitors hours, minutes, and cycles of valid arc
on. To view, rotate encoder. To reset, rotate encoder until [RESET] [YES] is
displayed. Press Menu button to display [RESET] [Done]. Displays turn to
0.0 guns. To calibrate, press and hold the trigger, allowing the wire to feed until
it stops. Then measure the wire, and subtract from 24 (24−wire length =
Cal Low.
. The Wire Feed Speed does not adjust in the Tech Menu, but does adjust
CAL HIGH in the Weld Process.
[CAL] [HIGH] Calibrate High: Calibrates high drive roll speed to provide
consistent wire feed speed between various spools of wire and spool
0.0 guns. To calibrate, press and hold the trigger, allowing the wire to feed until
it stops. Then measure the wire, and subtract from 24 (24−wire length =
Cal High.
. The Wire Feed Speed does not adjust in the Tech Menu, but does adjust
SOFT NUM in the Weld Process.
[SERL] [NUM] / [NA] Serial Number: This feature has not been imple-
mented.
OM-261726 Page 30
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Every
3
Months
Every
6
Months
805 521-A
OM-261726 Page 31
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1
2 Sec
RELE ASE .... TRIG GER Repeat
. All directions are in reference to the Over Temperature Errors: w [PFC] [ERRT]
front of the unit. All circuitry referred to Indicates a short or open in the thermal pro-
is located inside the unit. w [INV] [OT]
tection circuitry located in the primary pow-
1 Typical meter display may be in er factor correction circuitry of the unit. Con-
Over temperature condition in the primary tact a Factory Authorized Service Agent if
several segments. Each segment is inverter circuitry has occurred. Error will
shown for two seconds, and then this display is shown.
clear after the temperature has reached ac-
scrolls to the remaining segments ceptable levels. w [SEC] [ERRT]
of the display. The message then
repeats itself. Indicates a short or open in the thermal pro-
w [PFC] [OT] tection circuitry located in the weld output
Release Trigger Error: circuitry of the unit. Contact a Factory Au-
Over temperature condition in the primary thorized Service Agent if this display is
w [RELE] [ASE]/[TRIG] [GER] power factor correction circuitry has oc- shown.
Remote 14 receptacle contactor control curred. Error will clear after the temperature
(Pins A−B) must be opened before pro- has reached acceptable levels. Latching Errors:
ceeding. w [CLMP] [ERR]/[OVER] [VOLT]
w [SEC] [OT]
Communication Errors: Secondary clamp voltage too high.
w [SCOM] [SD] Over temperature of the weld output circuit- Straighten out or shorten weld cables. If this
ry has occurred. Error will clear after the does not correct the problem, contact a
Serial Communication to the memory card Factory Authorized Service Agent.
temperature has reached acceptable
board has been lost. To clear error, turn off
power. If error does not clear or happens
levels. w [CLMP] [ERR]/[OVER] [AMPS]
frequently, contact a Factory Authorized Temperature Sensor Failure: Secondary clamp amperage too high.
Service Agent. Straighten out or shorten weld cables. If this
w [INV] [ERRT] does not correct the problem, contact a
w [SCOM] [UI] Factory Authorized Service Agent.
Serial Communication to the user interface Indicates a short or open in the thermal pro- Not Valid Error:
card board has been lost. To clear error, turn tection circuitry located in the primary in-
off power. If error does not clear or happens w [Not] [Valid]
verter circuitry of the unit. Contact a Factory
frequently, contact a Factory Authorized Authorized Service Agent if this display is Indicates a non-allowable set-up on the
Service Agent. shown. front panel.
OM-261726 Page 32
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8-4. Troubleshooting
. 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.
Trouble Remedy
No weld output; unit completely Place machine power switch in On position (see Section 6-1).
inoperative.
Erratic or improper weld output. Lay weld cables out straight, do not leave weld cables coiled.
No control of weld output. Make sure Material Amperage control is in proper position (see Section 6-1).
Lack of high frequency; difficulty in Select proper size tungsten (see Section 11-1).
starting GTAW arc.
No weld output; fan does not run. Place line disconnect switch in On position (see Section 5-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11).
Check for proper input power connections (see Section 5-10 or 5-11).
No weld output; fan on. Check connection to remote control receptacle (see Section 5-2).
Fan not operating; weld output Check for and remove anything blocking fan movement.
available.
Have Factory Authorized Service Agent check fan motor.
OM-261726 Page 33
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Trouble Remedy
Error message [CLMP] [ERR] [OVER] Contact a Factory Authorized Service Agent.
[VOLT] is displayed.
Error message [CLMP] [ERR] [OVER] Contact a Factory Authorized Service Agent.
[AMPS] is displayed.
OM-261726 Page 34
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Notes
262 672-C
Work
Weld Zone
11, 12
50 ft
(15 m)
10
9 14
8
13 2
4 5 6
Best Practices
Not Followed
OM-261726 Page 37
10-3. Recommended Installation To Reduce HF Interference
Weld Zone 7
3 50 ft
(15 m)
50 ft
(15 m)
1
6
2
8
8
Ground all metal ob-
jects and all wiring in
welding zone using
#12 AWG wire.
Ground
workpiece if
required by
Nonmetal
Building codes.
9
Best Practices Followed
Metal Building
8
8
11
10
1 High-Frequency Source (welding 5 Conduit Joint Bonding and Grounding Metal Building Requirements
power source with built-in HF or
Electrically join (bond) all conduit sections 9 Metal Building Panel Bonding
separate HF unit)
using copper straps or braided wire. Methods
Ground metal machine case (clean paint
Ground conduit every 50 ft (15 m). Bolt or weld building panels together, install
from around hole in case, and use case
screw), work output terminal, line discon- 6 Water Pipes and Fixtures copper straps or braided wire across
nect device, input supply, and worktable. seams, and ground frame.
2 Center Point of Welding Zone Ground water pipes every 50 ft (15 m).
10 Windows and Doorways
Midpoint between high-frequency source 7 External Power or Telephone Lines Cover all windows and doorways with
and welding torch. grounded copper screen of not more than
3 Welding Zone Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines. 1/4 in (6.4 mm) mesh.
A circle 50 ft (15 m) from center point in all 11 Overhead Door Track
directions. 8 Grounding Rod
4 Weld Output Cables Ground the track.
Consult the National Electrical Code for
Keep cables short and close together. specifications.
OM-261726 Page 38
SECTION 11 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2016-10
Whenever possible and practical, use DC weld output instead of AC weld output.
11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
♦Typical argon shielding gas flow rates are 10 to 25 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS).
1 Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
1-1/2 To 4 Times
Radial Grinding Electrode Diameter 2 Tungsten Electrode
Causes Wandering Arc A 2% ceriated tungsten is recommended.
2 4
3 3 Ideal Grind Angle Range: 15° to 30°
15° to 30° . 30 degrees is the recommended elec-
trode grind angle.
4 Straight Ground
1 Grind lengthwise, not radial.
Wrong Tungsten
Ideal Tungsten Preparation − Stable Arc
Preparation
OM-261726 Page 39
SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW)
12-1. Positioning The Torch
! 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
3 an approved respirator. Read
MSDS for safety information.
Consider using cerium or lantha-
2 num based tungsten instead of
thoriated. Thorium dust contains
low-level radioactive material.
Properly dispose of grinder dust
in an environmentally safe way.
4 Wear proper face, hand, and
body protection. Keep flam-
mables away.
90° 1 Workpiece
1 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)
10−15° 5 Gas Cup
4 6 Tungsten Electrode
Select and prepare tungsten according
5 to Section 11.
10−25° 6 Guidelines:
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate
shielding gas coverage. (For example,
5 if tungsten is 1/16 in. diameter, gas cup
6
should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the
tungsten extends out gas cup of torch.
The tungsten extension should be no
1/16 in. greater than the inside diameter of the
gas cup.
3/16 in. Arc length is the distance from the
tungsten to the workpiece.
Bottom View Of Gas Cup
OM-261726 Page 40
12-2. Torch Movement During Welding
Tungsten Without Filler Rod
75° 15°
Welding direction
20°
90°
70°
75°
20°
15°
10°
20-40°
90°
75° 75°
15°
15°
30°
ST-162 003 / S-0792
OM-261726 Page 41
SECTION 13 − STICK WELDING (SMAW) GUIDELINES
13-1. Stick Welding Procedure
! Weld current starts when
electrode touches work-
piece.
! Weld current can damage
electronic parts in vehicles.
Disconnect both battery
Tools Needed: Equipment Needed: cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.
. Always wear appropriate per-
sonal protective clothing.
1 Workpiece
Make sure workpiece is clean be-
fore welding.
2 Work Clamp
Place as close to the weld as
Constant Current possible.
Welding Power Source 3 Electrode
Before striking an arc, insert an
electrode in the electrode holder. A
small diameter electrode requires
less current than a large one. Fol-
low recommendations of the elec-
trode manufacturer when setting
weld amperage (see Section
13-2).
5
4 Insulated Electrode Holder
4
5 Electrode Holder Position
2
6 Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound. Correct
arc length is related to electrode di-
ameter. Examine the weld bead to
determine if the arc length is cor-
3 rect.
Arc length for 1/16 and 3/32 in. dia-
6 meter electrodes should be about
1/16 in. (1.6 mm); arc length for 1/8
1 7 and 5/32 in. electrodes should be
about 1/8 in. (3 mm).
7 Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
OM-261726 Page 42
13-2. Electrode and Amperage Selection Chart
AMPERAGE
RANGE
PENETRATION
ELECTRODE
ELECTRODE
POSITION
DIAMETER
USAGE
DC*
AC
100
150
200
250
300
350
400
450
50
3
S-0049 / S-0050
OM-261726 Page 43
13-4. Positioning Electrode Holder
1 End View Of Work Angle
2 Side View Of Electrode
Angle
After learning to start and hold
an arc, practice running beads
1
of weld metal on flat plates using
a full electrode.
10°-30° Hold the electrode nearly per-
2
pendicular to the work, although
90° 90°
tilting it ahead (in the direction of
travel) will be helpful.
10°-30°
1 45° 2
45°
Fillet Welds
S-0060
2 3
5
1
S-0053-A
S-0052-B
OM-261726 Page 44
13-7. Conditions That Affect Weld Bead Shape
Electrode Angle
Drag
Spatter
Arc Length
Too Short Normal Too Long
Travel Speed
Slow Normal Fast
S-0061
S-0054-A
2 3
S-0063 / S-0064
OM-261726 Page 45
13-10. Welding Groove (Butt) Joints
1 Tack Welds
Prevent butt joint distortion by tack
welding the materials in position
before final weld.
Workpiece distortion occurs when
heat is applied locally to a joint.
1 One side of a metal plate will “curl”
up toward the weld. Distortion will
2 also cause the edges of a butt joint
to pull together ahead of the elec-
trode as the weld cools.
2 Square Groove Weld
3 Single V-Groove Weld
4 Double V-Groove Weld
Materials up to 3/16 in. (5 mm)
thick can often be welded without
special preparation using the
square groove weld. However,
when welding thicker materials it
may be necessary to prepare the
edges (V-groove) of butt joints to
30° ensure good welds.
1/16 in.
(1.6 mm) 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
3 4 and when, regardless of thickness,
you can weld from one side only.
Create a 30 degree bevel with oxy-
acetylene or plasma cutting equip-
ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
S-0062
45°
Or
2 2
Less 3
OM-261726 Page 46
13-12. Weld Test
1 Vise
2 Weld Joint
3 Hammer
Strike the weld joint in the direction shown. A good weld
bends over but does not break.
3
If the weld breaks, examine it to determine the cause.
If the weld is porous (many holes), the arc length was
3 probably too long.
2 To 3 in. If the weld contains bits of slag, the arc may have been
(51-76 mm) too long or the electrode was moved incorrectly which
2 To 3 in. allowed molten slag to be trapped in the weld. This may
(51-76 mm) happen on a V-groove joint made in several layers and
2 2 calls for additional cleaning between layers.
1/4 in.
(6.4 mm) 1 1 If the original beveled surface is visible the material was
not fully melted which is often caused by insufficient
heat or too fast a travel speed. S-0057-B
13-13. Troubleshooting
Porosity − small cavities or holes resulting from gas pockets in weld metal.
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.
Amperage too high for electrode. Decrease amperage or select larger electrode.
Arc length too long or voltage too high. Reduce arc length or voltage.
Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding
weld bead.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
OM-261726 Page 47
Lack Of Penetration − shallow fusion between weld metal and base metal.
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
Distortion − contraction of weld metal during welding that forces base metal to move.
Excessive heat input. Use restraint (clamp) to hold base metal in position.
OM-261726 Page 48
Effective January 1, 2016
(Equipment with a serial number preface of MG or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
for your local EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
Within the warranty periods listed below, Miller will repair or replace * Induction Heating Coils and Blankets, Cables, and
any warranted parts or components that fail due to such defects in Non-Electronic Controls
Your distributor also gives material or workmanship. Miller must be notified in writing within * M-Guns
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
Service followed. If notification is submitted as an online warranty claim, the
You always get the fast, * Replacement Parts (No labor)
claim must include a detailed description of the fault and the
reliable response you * Roughneck Guns
troubleshooting steps taken to identify failed components and the
need. Most replacement cause of their failure. * Spoolmate Spoolguns
parts can be in your Miller’s True Blue® Limited Warranty shall not apply to:
Miller shall honor warranty claims on warranted equipment listed
hands in 24 hours. below in the event of such a failure within the warranty time periods. 1. Consumable components; such as contact tips,
All warranty time periods start on the delivery date of the equipment cutting nozzles, contactors, brushes, relays, work
Support to the original end-user purchaser, and not to exceed twelve months station table tops and welding curtains, or parts that
Need fast answers to the after the equipment is shipped to a North American distributor or fail due to normal wear. (Exception: brushes and
tough welding questions? eighteen months after the equipment is shipped to an International relays are covered on all engine-driven products.)
Contact your distributor. distributor. 2. Items furnished by Miller, but manufactured by others,
The expertise of the 1. 5 Years Parts — 3 Years Labor such as engines or trade accessories. These items are
distributor and Miller is * Original Main Power Rectifiers Only to Include SCRs, covered by the manufacturer’s warranty, if any.
there to help you, every Diodes, and Discrete Rectifier Modules 3. Equipment that has been modified by any party other than
step of the way. 2. 3 Years — Parts and Labor Miller, or equipment that has been improperly installed,
* Auto-Darkening Helmet Lenses (Except Classic improperly operated or misused based upon industry
Series) (No Labor) standards, or equipment which has not had reasonable
* Engine Driven Welder/Generators and necessary maintenance, or equipment which has
(NOTE: Engines are Warranted Separately by the been used for operation outside of the specifications for
Engine Manufacturer.) the equipment.
* Inverter Power Sources (Unless Otherwise Stated) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Plasma Arc Cutting Power Sources USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Process Controllers MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
3. 2 Years — Parts and Labor replacement; or, where authorized in writing by Miller in appropriate
* Auto-Darkening Helmet Lenses − Classic Series Only cases, (3) the reasonable cost of repair or replacement at an
(No Labor) authorized Miller service station; or (4) payment of or credit for the
* Fume Extractors − Capture 5, Filtair 400 and Industrial purchase price (less reasonable depreciation based upon actual
Collector Series use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
4. 1 Year — Parts and Labor Unless Specified Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
* Automatic Motion Devices as determined by Miller. Therefore no compensation or
* CoolBelt and CoolBand Blower Unit (No Labor) reimbursement for transportation costs of any kind will be allowed.
* Desiccant Air Dryer System TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* External Monitoring Equipment and Sensors PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Field Options REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
(NOTE: Field options are covered for the remaining DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
warranty period of the product they are installed in, CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
or for a minimum of one year — whichever is
LEGAL THEORY.
greater.)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* RFCS Foot Controls (Except RFCS-RJ45) IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
* Fume Extractors − Filtair 130, MWX and SWX Series TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* ICE/XT Plasma Cutting Torches (No Labor) BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* Induction Heating Power Sources, Coolers OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
(NOTE: Digital Recorders are Warranted Separately DEALING, INCLUDING ANY IMPLIED WARRANTY OF
by the Manufacturer.) MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* LiveArc Welding Performance Management System
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
* Load Banks MILLER.
* Motor-Driven Guns (except Spoolmate Spoolguns) Some states in the U.S.A. do not allow limitations of how long an
* PAPR Blower Unit (No Labor) implied warranty lasts, or the exclusion of incidental, indirect,
* Positioners and Controllers special or consequential damages, so the above limitation or
* Racks exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
* Water Coolant Systems
the extent that they may not be waived, the limitations and
* TIG Torches (No Labor) exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2016-01
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01