Miller HF 5000 CE Owner's manual

Brand: Miller

Model: HF 5000 CE

Category: Welding System

Type: Owner's manual

This manual is also suitable for

LK290315D

Processes

TIG (GTAW) Welding

HF 5000

OM−235 241A 2009−09

Eff w/ LK230047D

Description

OWNER’S MANUAL

Visit our website at

www.MillerWelds.com

Stick (SMAW) Welding

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 which exact part you may need to fix the problem.

Warranty and service information for your particular model are also

provided.

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 or individual catalog sheets.

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

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − DEFINITIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Warning Label Definitions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. WEEE Symbol (For Products Sold Within The EU) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Symbols And Definitions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Serial Number And Rating Label Location 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Specifications 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Duty Cycle And Overheating 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Selecting A Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Weld Output Terminals And Selecting Cable Sizes* 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Installing Gas Supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Connecting Remote Control 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Rear Panel Receptacle Information 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Front Panel Receptacle Information 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Typical Connection To Power Source 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Input Power Connection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Front Panel Controls 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Initial Setup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Memory Control 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Resetting Unit To Factory Default Settings 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Selecting Remote Control 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. 2T Or 4T Trigger Mode Selection 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Process Control 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Pulse Control 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Sequence Control 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Lift-ArcE And HF TIG Start Procedures 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Troubleshooting Table 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Temperature/Ammeter Help Displays 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − ELECTRICAL DIAGRAMS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − HIGH FREQUENCY 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Welding Processes Requiring High Frequency 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Incorrect Installation 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Correct Installation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER

MACHINES 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 26. . . . . . . .

8-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter

Machines 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Positioning The Torch 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Torch Movement During Welding 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Positioning Torch Tungsten For Various Weld Joints 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy de

clares that the product(s) identified in this declaration conform to the essential requirements and

provisions of the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

HF 5000 V29 012 345

Council Directives:

S 2006/95/EC Low Voltage

S 2004/108/EC Electromagnetic Compatibility

S 2006/42/EEC Machinery Directive

Standards:

S IEC 609741 Arc Welding Equipment  Welding Power Sources: edition 3, 200507.

S IEC 609743 Arc Welding Equipment – Arc Striking and Stabilizing Devices: edition 2.0, 200711.

S IEC 6097410 Arc Welding Equipment Electromagnetic Compatibility Requirements: edition 2.0, 200708

S EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding,

arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic

fields (0Hz300Hz)

EU Signatory:

_____________________________________________________________________________

Mark Lowther

Date of Declaration

EUROPEAN DIRECTOR, TECHNOLOGY & PRODUCT DEVELOPMENT

September 10, 2009

956 142 702

OM-235 241 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _2009−08

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic

wire welding, the wire, wire reel, drive roll housing,

and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

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

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, 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

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

is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter weld-

ing power sources AFTER removal of inputpower.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.

D Allow cooling period before working on equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

OM-235 241 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.

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

D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,

coatings, cleaners, and degreasers.

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 protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or wool) and foot protection.

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 closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (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 oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

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.

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 shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF

)

can affect ImplantedMedical 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 can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Shielding 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 shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder 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.

OM-235 241 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu-

ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING 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 for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or

servicing unit. Read the safety information at

the beginning of the manual and in each

section.

D Use only genuine replacement parts from the manufacturer.

D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local

codes.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

OM-235 241 Page 4

1-4. California Proposition 65 Warnings

Welding or cutting equipment 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.)

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA 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 Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—

phone for Region 5, Chicago, is 312-353-2220, website:

www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East West

Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:

www.cpsc.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na-

tional Institute for Occupational Safety and Health (NIOSH), 1600

Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:

www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). Welding current creates an EMF field

around the welding circuit and welding equipment. EMF fields may inter-

fere with some medical implants, e.g. pacemakers. Protective

measures for persons wearing medical implants have to be taken. For

example, access restrictions for passers−by or individual risk assess-

ment for welders. All welders should use the following procedures in

order to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

OM-235 241 Page 5

SECTION 2 − DEFINITIONS

2-1. Warning Label Definitions

956.142.630-A

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

;l g

;l d

;

;l g

;l d

;

;lg

;l d

;

;l d

;

1.3

2.3

1.2

2.2

3.2

1.1

2.1

3.1

4.1

3.3

Warning! Watch Out! There are

possible hazards as shown by the

symbols.

1 Electric shock from welding

electrode or wiring can kill.

1.1 Wear dry insulating gloves.

Do not touch electrode with

bare hand. Do not wear wet or

damaged gloves.

1.2 Protect yourself from electric

shock by insulating yourself

from work and ground.

1.3 Disconnect input plug or

power before working on

machine.

2 Breathing welding fumes can

be hazardous to your health.

2.1 Keep your head out of the

fumes.

2.2 Use forced ventilation or local

exhaust to remove the fumes.

2.3 Use ventilating fan to remove

fumes.

3 Welding sparks can cause

explosion or fire.

3.1 Keep flammables away from

welding. Do not weld near

flammables.

3.2 Welding sparks can cause

fires. Have a fire extinguisher

nearby, and have a

watchperson ready to use it.

3.3 Do not weld on drums or any

closed containers.

4 Arc rays can burn eyes and

injure skin.

4.1 Wear hat and safety glasses.

Use ear protection and button

shirt collar. Use welding

helmet with correct shade of

filter. Wear complete body

protection.

5 Become trained and read the

instructions before working on

the machine or welding.

6 Do not remove or paint over

(cover) the label.

1 Warning! Watch Out! There

are possible hazards as

shown by the symbols.

2 Moving parts, such as fans,

can cut fingers and hands and

cause injury. Keep away from

moving parts.

956.142.629-A

OM-235 241 Page 6

2-2. WEEE Symbol (For Products Sold Within The EU)

Do not discard this product (where

applicable) with general waste.

Reuse or recycle Waste Electrical

and Electronic Equipment (WEEE)

by disposing at a designated collec-

tion facility.

Contact your local recycling office

or your local distributor for further

information.

2-3. Symbols And Definitions

Amperes

Volts Alternating Current

Protective Earth

(Ground)

Remote On Off Single Phase

Line Connection

Water (Coolant) In-

put

Water (Coolant)

Output

Voltage Input

Increase Decrease HF Start (TIG)

Remote Standard

(2T Trigger Mode)

Remote

(4T Trigger Mode)

Lift-Arc (TIG)

Gas Tungsten Arc

Welding (GTAW)

Shielded Metal Arc

Welding (SMAW)

Primary Current

Primary Voltage

I1max

Rated Maximum

Supply Current

I1eff

Maximum Effective

Supply Current

Rated Welding

Current

Voltage Peak

Suitable For Areas

Of Increased

Shock Hazard

Set-Up

Duty Cycle

Degree Of

Protection

Circuit Breakers Percent

Pulse

Hertz

Read Instructions

Before Operation

Gas Output

Gas Input Note Adjust

Recycle or Dis-

pose of used

coolant in an envir-

onmentally safe

way

Gas Preflow Time

Amps Initial

Initial Slope Time

Final Slope Time

Amps Final

Gas Postflow Time

Amps Background

OM-235 241 Page 7

SECTION 3 − INSTALLATION

3-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or

rated output. For future reference, write serial number in space provided on cover of this manual.

3-2. Specifications

Type Of Input

Power

Welding Power Source

Type

Welding

Voltage

Range

Welding

Current

Range

Rated Welding Output Overall Dimensions Weight

115 Volts AC

Single-Phase

500mA

50/60 Hz

XMT 350/304/456 And

Standard Constant Current

Welding Power Source

10-95 V 5-450 A 400 A @ 34 VDC,

100% Duty Cycle

Length: 420 mm

Width: 250 mm

Height: 265mm

13 Kg

Duty Cycle is percentage of 10

minutes that unit can weld at rated

load without overheating.

If unit overheats, thermostat(s)

opens, output stops, and cooling

fan runs. Wait fifteen minutes for

unit to cool. Reduce amperage or

duty cycle before welding.

NOTICE − Exceeding duty cycle

can damage unit or gun and void

warranty.

3-3. Duty Cycle And Overheating

Overheating

A or V

Reduce Duty Cycle

Minutes

OM-235 241 Page 8

3-4. Selecting A Location

956.142.654

. Leave 500 mm free space on

sides with louvers.

(500 mm)

3-5. Weld Output Terminals And Selecting Cable Sizes*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is

30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable

size.

! Turn off power be-

fore connecting to

weld output termi-

nals.

! Do not use worn,

damaged, under-

sized, or poorly

spliced cables.

Weld Output

Terminals

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

30 m (100 ft) or Less

45 m

(150 ft)

60 m

(200 ft)

70 m

(250 ft)

90 m

(300 ft)

105 m

(350 ft)

120 m

(400 ft)

Welding

Amperes

10 − 60%

Duty

Cycle

(AWG)

60 − 100%

Duty

Cycle

(AWG)

10 − 100% Duty Cycle

(AWG)

100 20 (4) 20 (4) 20 (4) 30 (3) 35 (2) 50 (1) 60 (1/0) 60 (1/0)

150 30 (3) 30 (3) 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 95 (3/0)

200 30 (3) 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 120 (4/0)

250 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0)

2x70

(2 ea. 2/0)

2x70

(2 ea. 2/0)

300 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0)

2x70

(2 ea. 2/0)

2x95

(2 ea. 3/0)

2x95

(2 ea. 3/0)

350 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0)

2x70

(2 ea. 2/0)

2x95

(2 ea. 3/0)

2x95

(2 ea. 3/0)

2x120

(2 ea. 4/0)

400 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0)

2x70

(2 ea. 2/0)

2x95

(2 ea. 3/0)

2x120

(2 ea. 4/0)

2x120

(2 ea. 4/0)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

***For distances longer than those shown in this guide, call a factory applications representative. Milan Ref. S-0007-G 2009−08

OM-235 241 Page 9

3-6. Installing Gas Supply

956.142.654

1 Cylinder valve

Remove cap, stand to side of

valve, and open valve slightly.

Gas flow blows dust and dirt

from valve. Close valve.

2 Regulator/Flowmeter

Install so face is vertical.

3 Flow Adjust

Typical flow rate is 15 CFH

(cubic feet per hour) (4.5 L/

hr).

Make sure flow adjust is

closed when opening cylinder

to avoid damage to the flow-

meter.

4 Gas Input Fitting

Connect hose from shielding

gas supply regulator/flowmet-

er to gas in fitting. Fitting has

5/8-18 right-hand threads.

5 Gas Output Fitting

Connect shielding gas hose

from torch to gas out fitting.

Fitting has 3/8−19 BSPP

right-hand threads.

Tools Needed:

18 mm (11/16 in.)

3-7. Connecting Remote Control

AJ

NH

1. Remote 14 Receptacle

2. Keyway

3. Plug

4. Threaded Collar

To connect to receptacle,

align keyway, insert plug,

and tighten threaded collar.

Socket* Socket Information

A Remote control circuit common.

B Contact closure to A completes trigger control

circuit.

AMPERAGE

C 0 to +10 volts DC output to remote control.

D Remote control circuit common.

E 0 to +10 volts DC input command signal from

remote control.

*The remaining sockets are not used.

OM-235 241 Page 10

3-8. Rear Panel Receptacle Information

956.142.656

! Turn power off before making

connections.

1 Coolant Out Connection

Connect coolant return hose to coolant

out fitting.

2 Coolant In Connection

Connect coolant supply hose to

coolant in fitting.

3 Gas Input Connector

Connect gas supply hose to gas input

fitting (see Section 3-6).

4 115 V Input Power Cord

5 14-Pin Receptacle

Make connections between recept-

acle and matching receptacle on weld-

ing power source.

6 Positive (+) Input Receptacle

Connect cable from positive weld out-

put terminal of welding power source.

7 Negative (−) Input Receptacle

Connect cable from negative weld out-

put terminal of welding power source.

8 Supplementary Protector CB1

CB1 protects unit from overload.

3-9. Front Panel Receptacle Information

956.142.656

! Turn power off before making

connections.

1 On/Off Switch

Use switch to turn unit on and off.

2 Remote 14-Pin Receptacle

Make connections according to

Section 3-7.

3 Coolant In Connection

Connect torch return hose to coolant in

fitting.

4 Coolant Out Connection

Connect torch supply hose to coolant

out fitting.

5 Gas Out Connection (See

Section 3-6)

Connect torch supply hose to gas out

fitting.

6 Negative (−) Output Receptacle

Connect TIG torch when TIG welding,

or work cable when Stick welding.

7 Positive (+) Output Receptacle

Connect work cable when TIG weld-

ing, or electrode holder when Stick

welding.

OM-235 241 Page 11

3-10. Typical Connection To Power Source

1 HF 5000

2 Welding Power Source

3 Cooling System

4 Typical Interconnecting Cable

! Size power cables within the

interconnecting cable for

the required welding cur-

rent and duty cycle (see Sec-

tion 3-5). See welding power

source Owner’s Manual, and

following all applicable

codes when selecting cable

sizes.

Make interconnecting cable con-

nections as follows:

• Connect negative weld cable to

negative weld receptacle on

power supply

• Connect negative weld cable to

negative weld terminal on unit

• Connect positive weld cable to

positive weld receptacle on

power supply

• Connect positive weld cable to

positive weld terminal on unit

• Connect 14-pin plug to 14-pin re-

ceptacle on power supply.

• Connect 14-pin plug to 14-pin re-

ceptacle on rear panel of unit.

• Connect gas supply hose to gas

supply. See section 3-6.

• Connect gas supply hose to gas

in connection. See section 3-8.

• Connect coolant supply hose to

coolant out fitting on coolant re-

circulating system.

• Connect coolant supply hose to

coolant in fitting on unit.

• Connect coolant return hose to

coolant in fitting on coolant recir-

culating system.

• Connect coolant return hose to

coolant out fitting on unit.

956.142.654 / 956. 142..656 / 803 691 / 956.142.653

3-11. Input Power Connection

956.142.654

1 Input Power Cord

Be sure the power source can

supply the 115 VAC neces-

sary to power this unit.

OM-235 241 Page 12

SECTION 4 − OPERATION

4-1. Front Panel Controls

956.142.656

1 Power (On/Off )Switch

Use switch to turn unit on/off. Upon

power up, unit will recall and display

the last welding procedure, or fact-

ory default procedure.

The display on the unit will show

STCK if Stick was selected last.

The display on the unit will show 2T

or 4T if TIG welding.

2T or 4T trigger mode will display

based on last selection.

STCK, 2T, and/or 4T will display for

5 seconds, and then display preset

amperage.

2 Ammeter And Parameter

Display

Displays actual amperage while

welding. Meter also displays preset

parameters for any of the following

variables: time, frequency function,

setup.

3 Process Control Adjust

Use control to select welding pro-

cess and light corresponding LED.

Control is also used for initial setup,

memory setting, and recalling fact-

ory parameters.

4 Setup Control

Use control to change selected

parameter, as indicated by lit LED,

for either the Standard TIG or TIG

Pulse process.

5 Decrease Control

Use control to reduce value shown

on display.

6 Increase Control

Use control to increase value

shown on display.

7 Process Indicator LEDs

LEDs show the selected welding

process.

8 Pulse Parameter Indicator

LEDs

9 Sequence Indicator LEDs

LEDs show the TIG parameter se-

lected.

OM-235 241 Page 13

4-2. Initial Setup

956.142.656

1 Process Control Adjust

2 Setup Control

3 Decrease Control

4 Increase Control

5 Ammeter And Parameter

Display

6 Power Switch

To enter Initial Setup, turn power off.

Press and hold Increase and

Decrease controls and turn power

on. Continue to hold Increase and

Decrease controls until software

version clears display, and display

begins to flash, release Increase

and Decrease controls.

Upon power up TIG HF and Pulse

LEDs turn on, and the factory de-

fault of 400 flashes on the display.

Press the Setup control to scroll

through the following: power source

current range, current reading dis-

play, and TIG starting current.

Setting Power Source Current

Range:

Setting Maximum Amperage −

While display is flashing, press the

Increase and decrease controls un-

til amperage shown on display

matches the maximum value of the

welding power source (see welding

power source Owner’s Manual).

Maximum amperage range is 200 to

600 amps, with 400 amps being the

default.

Press Setup control to confirm set-

ting and continue Initial Setup.

Setting Minimum Amperage − While

display is flashing, press the In-

crease and decrease controls until

amperage shown on display

matches the minimum value of the

welding power source (see welding

power source Owner’s Manual).

Minimum amperage range is 5 to

200 amps, with 20 amps being the

default.

Press Setup control to confirm set-

ting and continue Initial Setup.

Setting Current Display Reading:

While display is flashing, press the

Increase and Decrease controls to

select CURR or NOCU (CURR is

the default). CURR is actual current

output of the power source. NOCU

is the percentage of the current out-

put of the power source.

Press Setup control to confirm set-

ting and continue Initial Setup.

Setting TIG Starting Current:

While display is flashing, press the

Increase and Decrease controls to

set the TIG start current. The start

current range is 10 to 200 amps, 20

amps is the default.

Press Setup control to confirm set-

ting

Turn power off to exit Initial Setup.

OM-235 241 Page 14

4-3. Memory Control

956.142.656

. The first three alphanumeric digits of

the display indicate the desired action

being requested for the selected

memory position.

. The fourth alphanumeric digit of the dis-

play shows the selected memory posi-

tion. If the fourth digit is −, than the re-

quested action is not valid for the selec-

ted memory position.

LOA − Loads the welding parameters previ-

ously stored by the operator from the spe-

cified memory position.

STO − Stores welding parameters set by

the operator to an operator specified

memory position.

DEL − Permanently deletes stored welding

parameters from a specified memory posi-

tion.

. All memory positions are empty when

machine leaves factory

. Document all welding parameters for

each memory position.

. Welding parameter data is stored until

intentionally deleted, or a recall of fact-

ory parameters is performed (see Sec-

tion 4-4).

1 Process Control

Use control to enter memory control and

confirm selected action.

2 Setup Control

Use control to exit memory control.

3 Decrease Control

Use control to scroll through the desired ac-

tions required for the selected memory pos-

itions, LOA, STO, and DEL.

4 Increase Control

Use control to scroll through memory posi-

tions 0−9.

5 Ammeter And Parameter Display

6 Power Switch

To create or change a welding paramet-

er memory position, proceed as follows:

Select desired process, Stick, TIG Lift, TIG

Lift Pulse, TIG HF, TIG HF Pulse.

Set or modify all desired parameters.

With power on, press and hold Process

control until LOA is displayed .

Press and hold Decrease control until STO

is displayed.

Press Increase control to select desired

memory position 0−9.

Press Process control until OK is dis-

played.

To Recall a welding parameter memory

position, proceed as follows:

Press and hold Process control until LOA is

displayed .

Press Increase control to select desired

memory position 0−9.

Press Process control until OK is dis-

played.

To delete welding parameters from a

memory position, proceed as follows:

Press and hold Process control until LOA is

displayed .

Press and hold Decrease control until DEL

is displayed.

Press Increase control to select desired

memory position 0−9.

Press and release Setup control to exit

memory control.

OM-235 241 Page 15

4-4. Resetting Unit To Factory Default Settings

956.142.656

. Document all welding

parameters for each

memory position.

. This procedure will delete

all operator specified

parameters, and recall all

factory parameters..

1 Process Control

2 Increase Control

3 Ammeter And Parameter

Display

4 Power Switch

Turn unit off. Press and hold-

ing the Process and Increase

controls, turn unit on, wait for

CLR to display before releas-

ing controls.

4-5. Selecting Remote Control

956.142.656

. Document all welding

parameters for each

memory position.

1 Setup Control

2 Decrease Control

3 Increase Control

4 Ammeter And Parameter

Display

5 Power Switch

Turn unit on. Press and hold

Setup control until INT or EXT

is displayed. Press Increase

or Decrease controls to

change between INT and

EXT.

Press Setup control, and OK

will display.

INT − indicates weld se-

quence is initiated when elec-

trode makes contact with

workpiece. INT should be

used for Stick, TIG Lift, and

TIG Lift with pulse only

EXT − indicates weld se-

quence is initiated with some

external type of remote con-

trol.

OM-235 241 Page 16

4-6. 2T Or 4T Trigger Mode Selection

956.142.656

. Document all welding

parameters for each

memory position.

1 Process Control

2 Decrease Control

3 Increase Control

4 Ammeter And Parameter

Display

5 Power Switch

Turn unit on. When welding

with any TIG process, the unit

will first display 2T of 4T.

To change between 2T and

4T, press the Process control

and 2T or 4T will display.

Press the Increase or

Decrease control to change,

after 5 seconds, weld amper-

age is displayed. Resume

welding.

Current (A)

Preflow

Initial Amps

Initial Slope

Final Slope

Postflow

Main Amps

Final Amps

Remote 2T Trigger Operation

Current (A)

Preflow

Initial Amps

Initial Slope

Final Slope

Postflow

Main Amps

Final Amps

P&R = Push and release trigger.

Remote 4T Trigger Operation

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Miller HF 5000 CE Owner's manual

Brand: Miller

Model: HF 5000 CE

Category: Welding System

Type: Owner's manual

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Miller HF 5000 CE Owner's manual

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Miller HF 5000 CE Owner's manual

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