OWNER S MANUAL - Miller
August 1973FORM: OM-313Effective with serial No. 72-61 2483MODELMODEL/STOCK NO.SERIAL/STYLE NO.OWNERSTwoFifty TwinTwoFiftyTwin-PSTOCK NO.901 973901 976DATE PURCHASEDMANUALMILLER ELECTRIC MFG. CO.APPLETON, WISCONSIN, USA 54911ADDITIONAL COPYPRICE 60 CENTSNWSA CODE NO. 4579U.S.
TABLE OF CONTENTSPage No.Paragraph No.SECTION 1SAFETY RULES FOR OPERATION OF ARC WELDING MACHINE1-1. General1 -2.Welding1 -3.Electrode Holder1Cables114. Code Conformance-111 -5. Parallel Connections1116. Power Disconnect Switch-1-7.11Polarity SwitchRange Switch8.-119. Exhaust Gases-11-10. Power Circuit Ground21-11. Containers Which Held Combustibles21-12. Hollow Castings (Welding of)1-13. Explosion Hazards21-14. Ventilation21-15. Solvents31-16. Fire Hazards31-17. Electrical Shock-Voltage1-18. Electrical Shock-Dampness31-19. Starting Under Load1-20. Face Protection31-21. Eye Protection1-22. Clothing31-23. Hot Metal Burns44Grinding and Chipping1-25. Compressed Gas Cylinder44INTRODUCTION2-1. y3.2 -4.SECTION 355INSTALLATION3-1. Line Disconnect Switch333---Primary ConnectionsWelding Connections4. Secondary-1.444---8Duty Cycle5. Volt-Ampere Curve84.666----8SEQUENCE OF OPERATION1. Shielded Metal-ArcWelding (SMAW)8MAINTENANCESECTION 6673. On-Off Power SwitchSECTION 5567Range Selector Switch4-2. Fine Current Control & Current Indicator-6OPERATIONSECTION 44552. Location3.331-24.SECTION 221. Power Factor CorrectionCapacitors82. Transformer93. Fan Motor94.InputSECTION 7PARTS LISTPower & Welding CablesTROUBLESHOOTING9
SECTION1-1- SAFETY RULESFOR OPERATION OF ARC WELDING MACHINE1. GENERALThese rulesapply to ac and dc welding generators. ac transformer and ac/dc welding machines, and dc transformer rectifier welding machines.Inarc-welding operations, where electrically energized partsexposed, observe the following safety rules to insure maximum personal safety and protect nearby persons.areFailure to observe these safety precautions may expose notonly you, but fellow workers as well, to serious injuries. Oncethese rules are learned and kept in mind, proceed with maximum assurance.1 -2. WELDING CABLESDONToverloadFigurecables, (Figure 1-1)1-3. DontDONTuseuseElectrode Holder with defectivejawselectrode holder with loose cable connections.Keep the connections oftight at all times.theelectrodelead to the holderfully insulated electrode holders (and withouttruding screwheads.)Use onlyNever touch two electrode holders from two separatemachines at the same time.prowelding1 -4. CODE CONFORMANCEThe machine and its equipment must be installed and maintained in accordance with the National Electrical Code andlocal requirements.Figure1-1. Dontoverload cables1 -5. PARALLEL CONNECTIONSNEVERuse welding cables at currents in excess of their ratedcapacity. It will cause overheating and rapid deterioration ofthe insulation. It is also uneconomical.See1DONTuse worn ordiagrams-in the instruction manualapplyingtothe weldmachine used.ing6. POWER DISCONNECT SWITCHpoorly connected cables. )Figure 1-2)If thewelding machine doesswitch, installone at or nearnot includethe machine.apower disconnect1 .7. POLARITY SWITCHDONToperate the polarity switch under load.The polarity switch (when supplied) is provided for changingthe electrode lead from positive (reverse polarity) to negative(straight polarity). Never move it while under the load of awelding current. Operate this switch only while the machineis idling and the welding Circuit 5 open. The potential dangers of opening the Circuit while carrying high current are:Figure 1-2. Dontuse worn orThe person throwing the switch may receivefrom this arcing.surfaces of thea severeburnthesections ofcableobjects, heoperate the range switch under load.range switchlwhen supplied)is provided for obteiningIt must never be operated while thethe load of welding current. Operate therange switch only while the machine is idling and the weldingcircuit is open. The potential danger of switching the Circuitwhile carrying high current is the formation of an arc berequiredgrounded metallicmay be injured andcurrentsettings.machine is underfire may result if combustible materials such as oil or greaseare in the vicinity. The efficiency and quality of welding willbe improved by elimination of these dangerous grounds, andby keeping connections tight.-2.contact1- 8. RANGE SWITCHinsulation with rubber and friction tapes. Tighten allcable connections and adequately insulate any joints where aconnector may have an exposed conductive part. In additionto the potential hazard to life, a hazard occurs when exposed1An arc will form between theswitch and severely burn them.poorly connected cablesInspect the cables frequently. Immediately repair all breaksin1.the contact surface which will severely burn them.Repeated occurrences of this arcing will eventually preventoperation of the contacts.tween3. ELECTRODE . EXHAUST GASES(Figure1-3)DONTingKeep the jaws of the electrode holder tight and the grippingsurfaces in good condition to provide close contact with theelectrodes. Defective jaws will permit the electrode to wobble, making control of the welding operations difficult.use gas engine units in Confined spaces without ventthe exhaust gases. )Figure 1-4)If gasoline or other fuelindoors, provide meansdriventowelding machines are operatedpipe the exhaust gases to the Outside air to avoid carbon monoxidepoisoning.OM-313 Page 1
When you know the container heldnot readily dissolve in water:- 1.Cleanoutthouroughly withasteamliquidorgasorawhich willcleansing agentand purge all air or inert with a gas such as carbon dioxideor nitrogen before repairing. Carbon dioxide is heavierthan air and will tendopening is at the top.2.3.Use steamUseor4.alightmaterial,strong caustic soda solutiontoclean outheavyBesureorBeoilsto purge all air or inert with a gas, such as nitrocarbon dioxide, no matter how well you havecleaned. There may still be traces of oil, grease,readily oxidizable material under the seams.Vent exhaust gasescarefulwhencleaning withsteamororcaustic sodaotherweargoggles and gloves.1-10. POWER CIRCUIT GROUNDDONTuse welding machine without grounding frame(Figure 1-5)case.clean outin the container if thegrease.genFigure 1-4.toremaintoorDONTclean where there is poor ventilation.Ventilationis necessarytocarry away harmfulorexplosivevapors.DONTWhenuse aclean where thereareopen flames.scraping or hammering to remove heavy sludge or scale,spark resistive tool and keep it wet to avoid sparks.Keep your head andpossible,armsasfar away from your workas1-12. HOLLOW CASTINGSDONTweld on hollow (cored) castings that have notproperly vented. The casting may explode. (Figure 1-6)--Figure 1-5. Ground framebeenor caseGround the ground cable of every power Circuit to preventshock by stray current. The potential danger isthat development of a stray current may give a fatal shockshould a person, for example, place one hand on the weldingmachine and the other on the switch box, or other groundedaccidentalequipment.Donotgroundpipelines carrying gasestoSI/orconduits carrying electrical conducliquidstors. Be sure conductors can safely carry the ground current.When connecting the welding machine, properly ground themachine frame or case.flammableand1-11. CONTAINERS WHiCH HELD COMBUSTIBLESweld on containers which have held combustible orDONTflammable materials or materials which, when heated, giveoff ftammabte or toxic vapors without proper cleaning, purging,orinerting.containers which have held flammableWeldingorcombustible materials may be extremely dangerous. To prevent a fireor explosion of the container, follow the recommendationsCuttingWelding Society Pamphlet A6.O WeldingContainers Which Have Held Combustibles.DONTdependof the Americanweldon aonyour eyesnoseorto1-6. DontFigureweldonhollow (cored) castings1-13. EXPLOSION HAZARDSordecide if it is safetoclosed container.Find Out what was in the container or use an explosimeter. Asmall amount of residual flammable gas or liquid canNEVER weld in or near explosive atmospheres. Such atmoscan be created by flammable gas leaks or by vaporsfrom flammable liquids (gasoline, alcohol, etc.) or by combustible dusts.pheres1.14. VENTILATIONverycause aserious explosion.NEVERuseDONToxygen to ventilateacontainer.When you know the container heldreadily dissolve in water:1.agasoutaspermit introduction ofaswillas1967.Always provide adequate ventilation by blowers, airother acceptable means: Never use compressed oxygen. The depletion of the oxygen supply, the heat of weldoring, and the fumesserious illness.given offBeforeweldingbesurethere isvide for release of air pressure.Page2amaycause severediscomfortor apossible.When toxic fumes from lead2.ventilation.welding in confined spaces, provide ventilation inaccordance with United States of American Standard Z49.1,lines,much wateradequateWhenliquid whichorwith water several times and then fill withfar as work permits, positioning container toFlushwaterweld in confined spaces withoutvent oropeningto proor cadmium bearing materials orother substances are present in harmful concentrations,always use an air supplied respirator.any
1-15. SOLVENTSDoelectrode on the table topmetallic surface. (Figure 1-7)greasing,Do not weld where ultravioletlight from the electric arc cancontaining even minute amounts of vapors fromas trichloroethylene or perchloroethylene. Ultraviolet light can decompose the vapors to form phosgene, ahighly toxic gas and other irritating products.penetrate air olvents such1-16. FIRE HAZARDSweldDONTnearcanflammableorcombustible materials.be causedmetal, by slag,Whenisitnotincontact with thegroundeduse,placenevertabletoporelectrode holder inanother metallic surface in contactwith welding ground. Provide an insulated hook or holder forthe electrode holder. A potential danger is that a holder incontact with the ground circuit provides a dead short circuiton the welding machine. If the machine should be started up,this short circuit would cause an excessive load on the machine and may damage the insulation.1-20. FACE PROTECTIONDONTby the arc, by contact with the heatedsparks. Keep combustibles at least 35 feetfrom the arc or suitably protected. If welding must be donein a particular area, move the combustibles away. If theycannot be moved, cover them completely with fire resistivescreens. Cover cracks or openings in floors or walls; sweepfloor free of combustibles and wet down, if wood, being surewelder wears insulation shoe coverings. Avoid welding on parFiresaweld where chlorinatedhydrocarbon vapors from decleaning, or spraying may reach or be drawn into airsurrounding the welding operation. The heat of the arc candecompose solvent vapors to form phosgane, a highly toxicgas and other irritating decomposition products.notin contact withorusecracked or defective helmetsorshields.Keep the helmet, hand shields, or face shield in good condition. If cracks occur in the fibre material, replace the shield,since the leakage of arc rays may cause serious burns.or1-21. EVE PROTECTIONNEVERcircumstances, lookunder anyatanelectricarcprotection.without eyetition walls in contact with combustibles. Heats metal onthe other side of partition wall being weded upon can ignitecombustibles in contact with the partition. Where other thanminor fire might develop, have a fire watcher stand-by withsuitable fire extinguishing equipment for at least one-halfhour after the welding is completed.a1-17. ELECTRICAL SHOCK-VOLTAGEOPEN power circuits beforechecking machines.Before working on the wiring, switches, controls, etc., openthe power line disconnect switch. In most welding shops thepower supply used for arc welding machines is 230 or 460volts, Openwelding orvoltages are usually less than 100 volts andvoltage drops are still lower. However, all ofthese voltages are capable of developing a harmful or fatalcurrent to the body.DONTcircuitarctouch electrically hotparts.NEVER touch any exposed or non-insulated part of thecables, cable connectors, clamps, electrode holders, electrodes, or the power supply equipment to prevent harmful orfatal electric shockorFigure 1-8, Useeyeprotectionat all timesburns.1-18. ELECTRICAL SHOCK-DAMPNESSNEVER work in a damp area without suitable insulation against shock. Keep hands, feet, and clothing dry at all times.To.prevent harmful body shocks, keep hands, feet and clothing dry. Never stand or lie in puddles of water, damp ground,or against grounded metal when welding without suitable insulation against shock. Always find a dry board or rubbermat to stand on when water, moisture, or perspiration cannotbe avoided. Dampness between the body and an energized orgroundedcurrenttometallic part lowers the resistance to the passage ofthe body which may produce a harmful or fatalshock. Salt in perspirationcontact resistances.seaorwaterdangerously lowersUIMakesuregoggles are used under the weldall times, particularly while gas shielded-that flashing helmet atwelding.arcIIIn some type of arc welding, such as gas shielded-arc welding,ultra-violet and infra-red radiation from the arc is particularlyintense and requires constant attention to avoid arc flashes tothewelder whenstrikinganarcand to avoid exposure toother welders.NEVER strike an arc without ascertaining that nearby pereither have the necessary protective equipment or arelooking in the opposite direction.sonsForin open areas, provide portable, nonshield persons nearby from the rays ofEye burns from the arc, through not generally perinjuries, are exceedingly painful. Such burns frewelding operationsref Iectingthearc.manentscreensquently referredIf the eyetoto asis focusedflashes,onthefeel like hot sand in the eye.without filter-glass proteccause retinal scarring and imarction, infra-red radiation canpaired vision. For eye burns consultyour first aid stationordoctor.NEVERFigure1-7, Dontleave electrode in contact withmetallic surface.leaveanuninsulatedelectrodeordefective plates.and shields mustbe ofthe latest Ameriglass plate provided in the helmetsreputable manufacture conforming toNationalcrackedholder,cracked, ill-fitting,The filtercan1-19. STARTING UNDER inguseInstitute, Standard Z2.1.filter platesfilter s.OM-313 Page 3
Keep a clean cover glass in front of the filter plate for theprotection thereof. Frequent renewal of these cover glasses isnecessary, since they become covered with spatter, reducingvision.Whenever it is necessary to grind or chip metal, wear protec.tive goggles specifically designed for this purpose. Serious eyeinjuries may result from failure to wear protective goggles.1-25. COMPRESSED GAS CYLINDERS1-22. thing.Wearheavy shoes, tightly laced. Keep clothing dry.Properstrikeanarconcompressed gas cylinder. Alwaysin regards to compressedafollowing precautionsobserve theg cylinders:anddry, oil-free clothing is essential for the weldersprotection. Clothing must not only keep off the spatter andmolten particles, but must also obstruct the rays of the arcand, when necessary, insulate the body from harmful electri1.Avoid accidental contact of the electrodes, electrodeholder, or other electrically energized parts with acompressed gas cylinder or any other pressure vessel.Serious accidentsfires may result.orcal currents.2.Wear leather or asbestos gloves at all times to protect thehands and wrists. Dark colored shirts are preferred to lightbecause light ones reflect arc rays to exposed parts ofbody. In the case of gas shielded-arc welding, light colorsonestheUse I.C.C.or DOT. cylinders. They are manufacturedmaintained in accordance with DOT. requireand are safe so long as they are properlymentshayidled. Dont drop cylinders.andreflective and may cause eye burns due to the inultra-violet rays given of f by the process. Avoid cottonfabrics when gas shielded-arc welding.3.Identify gas content by the name marked on the cylinder. If the cylinder is unmarked, do not use it. Returnit to the supplier. Do not rely on a color code.An4.Never use a cylinderintended purposes.aremoretensearcburnusuallyonthe skin resemblesmore severe.Clothingcana sunburn, except that it isbe made flame resistant byits contents for other thanortreatment with asolution of 3/4 pound of sodium stannate ingallon of water, then wrun9 out and dipped in a solution of1/4 pound ammonium sulphate per gallon of water. Dontwash clothing so prepared in water, but dry clean.15.6.Keepslag,Whenwelding operations are to be performed in vertical andoverhead positions, leather sleevelets. aprons, and in somecases leggings and ear plugs should be used to prevent severeaway from oxygencylinders andvalves.cylinders away from exposure to sparks, hotopen flame and all possible sources of ignition orexcessive heat.7.burns from spatter and molten metal.Keep oil and greasecylinderBe careful that cylinders are not placed so as to bea part of an electrical circuit. Avoid third rails,come1-23. HOT METAL BURNSNEVER pick up hotwires and electric8.objects. (Figure 1-9)9.Figure 1-9.Neverpickup hotobjectsNEVER pick up pieces of metal which have just been weldedor heated, or the stub ends of electrodes which have beendiscarded.transporting cylinders byWhenformwelding circuits.orcrane,usecradle platother suitable support.Never lift the cylinders byelectric magnets.slings, bythe capsorby10.Never11.Never try to mix any gases in12.Never try to refill13.Mark14.Send Emptysback to the15.Keep Emptysand Fulls16.Never tamper with or alter cylinder numbers or othermarkings. This is not only foolish but may be illegal.17,Do not tamper with18.If valves cannot inder.tag empty cylinders EmptyororMT.supplier promptly. 15,separate.change fittingsoncylinders.1-24. GRINDING AND CHIPPINGNEVERdoany chippinggoggles. (Figure 1-10)orgrindingwithoutmer orprotectivewrench.opened by hand,Notify supplier,do notuseham19.Protect cylinder valves from bumps, falls, falling objects, and from weather. Keep them covered withcylinder caps when moving cylinders.20,Keep valves closed21.See that your cylinders are clear of passageways andactive work areas and that they are secured againstonempty cylinders.falling,22.Ifadapter23.Figure 1-10. Never doprotective goggles.Page 4anychippingorgrinding withoutisrequired between cylinder and regulator,standard adapter. These may be obtainedfrom your supplier. Where right and left hand threadsare used on adapter, use two wrenches to insure leakproof connections.alwaysuseaDo not storecylinders inunventilatedareas.
SECTION es Input At RuledLoS Output 60Hz.Oimensionshoekw4520.711.83516.18.2208)260 Vults230 Volts460 Volts10390goio78653415.611.8 y5 2511.58.2Inches)250W30 Volts,Power30% Outy Cycle200 @ecPoctorLow 25-125oc78dcdc25051Low 20-887530 Volts.WithHigh 70-250Power50% OotyCycleHhtWdth0 th-332342--34035026-1/4152530% Ouly Cycle20051Pector.28 Volts,CorrectionShip 28 Volts,High 105-325Net.WithoutCorrectionWeightOoerull50% Outy Cycle NEMA RATIN jtheandabove electrical specifications Conform withcomply with ANSI Standard C87.1-1971.Rating EW 1-1971, Nema Class 11(30)NemaFigure 2-1. SpecificationsAA-gol g73-4Figure2-1.2-2.GENERALBlockDiagram24.Before the equipment is put into operation, the safety section at the front of this manual should be read completely.This will help avoid possible injury due so misuse or improperprepared especially for use in familiardesign, installation, operation, mainandtenance,troubleshooting of this equipment Allinformation presented herein should be given careful consideration to assure optimum performance of this equipmentThis manual has beenizing personnel2-2.SAFETYwith thewelding applications.TheRECEIVING-HANDLINGfollowingd
August 1973 FORM: OM-313 Effective with serial No. 72-612483 MODEL TwoFifty Twin TwoFifty Twin-P STOCKNO. 901 973 901 976 ADDITIONALCOPY PRICE 60CENTS MODEL/STOCKNO. SERIAL/STYLE NO. DATEPURCHASED OWNER SMANUAL MILLER ELECTRICMFG.CO. APPLETON,WISCONSIN, USA 54911 NWSACODENO.4579 U.S.
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er's Manual and the following Owner's Man‐ uals: Integrated Owner's Manual in the vehicle. Online Owner's Manual. MINI Motorer’s Guide App. Notes on updates can be found in the appendix of the printed Owner's Manual for the vehicle. Owner's Manual for Navigation, Entertainment, Communication Owner's Manual for Navigation, Entertainment,
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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 .File Size: 964KB
