Miller HF-20-1WG Owner's manual

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Processes

Description

TIG (GTAW) Welding

OM-610 029 820S

July 2002

High Frequency Arc Starter

HF-20-1WG

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog orindividual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. We know you don’t have time to do

it any other way.

That’s why when Niels Miller first started building arc welders in 1929,

he made sure his products offered long-lasting value and superior

quality. Like you, his customers couldn’t afford anything less. Miller

products had to be more than the best they could be. They had to be the

best you could buy.

Today, the people that build and sell Miller products continue 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 most out of your

Miller products. 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

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

– every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Miller offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

CERTIFICATE

NAME OF EQUIPMENT: MODEL NO.

SERIAL NO. DATE:

This equipment has been type-tested under standardized field test conditions as recommended

by the Joint Industry Committee on High-Frequency Stabilized Arc Welding Machines found to radiate

less than 10 microvolts per meter at a distance of one mile, the maximum allowable limit established

by the Federal Communications Commission for equipment of this type.

Installations using this equipment on the basis of these tests, may reasonably be expected to

meet the radiation limitations established by the Federal Communications Commission, only when

installed, operated and maintained as specified in the instruction book provided.

USER’S CERTIFICATION

The welding equipment identified above has been installed in accordance with the specific

instructions applicable to this model as outlined in the instruction book furnished. It is being used only

for the purpose for which it was intended and is being maintained and operated in accordance with the

manufacturer’s instructions

Date Installed Signed

The following terms are

used interchangeably

throughout this manual:

TIG = GTAW

Stick = SMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE

1-1. Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. General Precautions 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Arc Welding 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Standards Booklet Index 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. General Information And Safety 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Safety Alert Symbol And Signal Words 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – SPECIFICATIONS

3-1. Description 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – INSTALLATION OR RELOCATION

4-1. Location 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Coolant Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Gas Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Remote Hand Switch And Receptacle Connection 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Weld Input/Output Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Electrical Input Connections 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – OPERATOR CONTROLS

5-1. Process Selector Switch 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Power Switch 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. High Frequency Intensity Control 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Valve Control Switch 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Start Selector Switch 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Postflow Timer 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – SEQUENCE OF OPERATION

6-1. Gas Tungsten Arc Welding (GTAW) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Shutting Down 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – MAINTENANCE & TROUBLESHOOTING

7-1. Internal Cleaning 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Interconnecting Cords 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Spark Gaps 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Tungsten Electrode 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Troubleshooting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – ELECTRICAL DIAGRAMS

Diagram 8-1. Circuit Diagram For 115 Volts Models With Gas & Water Controls 22. . . . . . . . . . . . . . .

Diagram 8-2. Circuit Diagram For 230 Volts Models With Gas & Water Controls 22. . . . . . . . . . . . . .

SECTION 9 – CERTIFICATION FOR HIGH FREQUENCY ARC WELDING EQUIPMENT

9-1. General 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Definitions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. High-Frequency Radiation 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Location 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. General Installation Procedures 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6. Guidelines For Installation Of High-Frequency Assisted Arc Welding Power Sources 26. . . . .

9-7. Installation Guidelines Checklist 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – PARTS LIST

Figure 10-1. Main Assembly (HF-20-WG Illustrated) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-2. HF Panel (HF-20-2WG Illustrated) 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 10-3. Remote Hand Switch 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF CHARTS AND TABLES

Table 3-1. Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 7-1. Tungsten Size 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 7-2. Troubleshooting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

WARNING

This product, when used

for welding or cutting,

produces fumes or

gases which contain

chemicals known to the

State of California to

cause birth defects and,

in some cases, cancer.

(California Health &

Safety Code Section

25249.5 et seq.)

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SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various la-

bels, tags, and plates on the unit pertains to equipment

design, installation, operation, maintenance, and

troubleshooting which should be read, understood, and

followed for the safe and effective use of this equipment.

The nameplate of this unit uses international symbols

for labeling the front panel controls. The symbols also

appear at the appropriate section in the text.

B. Safety

The installation, operation, maintenance, and trouble-

shooting of arc welding equipment requires practices

and procedures which ensure personal safety and the

safety of others. Therefore, this equipment is to be in-

stalled, operated, and maintained only by qualified per-

sons in accordance with this manual and all applicable

codes such as, but not limited to, those listed at the end

of Section 1 – Safety Rules For Operation Of Arc Weld-

ing Power Source.

2-2. SAFETY ALERT SYMBOL AND SIGNAL

WORDS

The following safety alert symbol and signal words are

used throughout this manual to call attention to and

identify different levels of hazard and special instruc-

tions.

This safety alert symbol is used with the signal

words WARNING and CAUTION to call atten-

tion to the safety statements.

WARNING statements identify procedures or

practices which must be followed to avoid seri-

ous personal injury or loss of life.

CAUTION statements identify procedures or

practices which must be followed to avoid minor

personal injury or damage to this equipment.

IMPORTANT statements identify special instructions

necessary for the most efficient operation of this equip-

ment.

OM-610 Page 13

SECTION 3 – SPECIFICATIONS

Table 3-1. Specifications

HF-20-1WG

Model

Input

Volts AC

Rated Welding

Amps. 60%

Duty Cycle

Width Length Depth

Net Weight

Dimensions

1000

92 lbs. ( 41 kg )

115

20-1/4 in.

( 514 mm )

13-1/2 in.

( 343 mm )

15 in.

( 381 mm )

3-1. DESCRIPTION

This unit is a high-frequency arc stabilizer which super-

imposes high-frequency energy on either ac or dc power

supply weld outputs. It is designed primarily for use with

the Gas Tungsten Arc Welding (GTAW) process. How-

ever it can also be used for other processes requiring

arc initiation and stabilization such as Submerged Arc

Welding (SAW) and Plasma Arc Cutting (PAC) proc-

esses.

CAUTION: HIGH-FREQUENCY ENERGY

can damage equipment.

• Check with manufacturer of equipment to be

used with this unit to ensure that damage will

not occur.

Units are equipped with gas and water (coolant) valves

and a postflow timer. These units do not function proper-

ly on welding power sources equipped with a primary

contactor, if the primary contactor provides on/off con-

trol of the welding arc. The welding power source must

be energized at all times for units to function properly.

SECTION 4 – INSTALLATION OR RELOCATION

4-1. LOCATION

IMPORTANT: Read entire Section 9 regarding high-

frequency equipment location and installation require-

ments before beginning installation.

Locate the high-frequency unit close to the work station.

This will allow the electrode and work cables to be kept

as short as possible, thereby minimizing high-frequency

radiation and losses.

4-2. COOLANT CONNECTIONS (Figure 4-1)

COOLANT

IN

COOLANT

OUT

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down unit and welding power source

(stop and disable engine on engine driven

equipment).

• Disconnect input power employing lockout/

tagging procedures before making coolant

connections.

Lockout/tagging procedures consist of remov-

ing plug from receptacle, padlocking line discon-

nect switch in open position, removing fuses

from fuse box, or shutting off and red-tagging

circuit breaker or other disconnecting device.

CAUTION: OVERHEATING GAS TUNGSTEN

ARC WELDING (GTAW) TORCH can damage

unit.

• Do not connect coolant hoses to the high fre-

quency unit if a recirculating coolant system is

used. Make connections from the torch

directly to the coolant system.

1. Connect a hose of suitable length and construc-

tion from coolant source to the COOLANT IN

connector on the front panel.

2. Connect the torch coolant hose to the COOLANT

OUT connector.

Both coolant connectors have 5/8-18 in. left-hand

threads.

OM-610 Page 14

ST-070 989-B

Welding

Power

Work (–)

Electrode (+)

Source

Electrode

Work

Torch

AC Input Power Cord Gas In Coolant In

Remote

Receptacle

Work

Figure 4-1. Interconnection Diagram

4-3. GAS CONNECTIONS (Figure 4-1)

GAS

IN

GAS

OUT

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down unit and welding power source

(stop and disable engine on engine driven

equipment).

• Disconnect input power employing lockout/

tagging procedures before making gas con-

nections.

Lockout/tagging procedures consist of remov-

ing plug from receptacle, padlocking line discon-

nect switch in open position, removing fuses

from fuse box, or shutting off and red-tagging

circuit breaker or other disconnecting device.

1. Connect a hose of suitable length and construc-

tion from shielding gas supply to the GAS IN con-

nector on the front panel. The gas must be con-

trolled with the aid of a regulator and flowmeter.

2. Connect the torch shielding gas hose to the GAS

OUT connector.

Both gas connectors have 5/8-18 in. right-hand threads.

4-4. REMOTE HAND SWITCH AND RECEPTACLE

CONNECTION (Figure 4-1)

REMOTE

A normally-closed Remote Hand Switch (with leads and

plug) is supplied to provide on/off control of high

frequency, gas, and coolant. The Remote Hand Switch

must be connected to the REMOTE receptacle on the

front panel for unit to function whenever the START SE-

LECTOR switch is in HIGH FREQUENCY position.

To connect switch to REMOTE receptacle, fully insert

switch plug (attached to leads) into receptacle, and

rotate plug fully clockwise until secure. A hose clamp

(attached to switch) is supplied to secure the switch to

the torch. Install and secure switch onto torch handle in

desired location.

4-5. WELD INPUT/OUTPUT CONNECTIONS (Fig-

ure 4-1)

ELECTRODE WORK

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Shut down unit and welding power source

(stop and disable engine on engine driven

equipment).

• Disconnect input power employing lockout/

tagging procedures before making connec-

tions.

Lockout/tagging procedures consist of remov-

ing plug from receptacle, padlocking line discon-

nect switch in open position, removing fuses

from fuse box, or shutting off and red-tagging

circuit breaker or other disconnecting device.

IMPORTANT: Refer to the welding power source Own-

er’s Manual for proper secondary cable sizes.

Four terminals are provided on the front panel for weld

input/output connections. To make connections, pro-

ceed as follows:

1. Connect welding cables from the welding power

source to the ELECTRODE and WORK termi-

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