Miller LC250717 Owner's manual

Category
Welding System
Type
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 Owners 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
manufacturers 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-
ers 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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Miller LC250717 Owner's manual

Category
Welding System
Type
Owner's manual
This manual is also suitable for

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