Arc Welding Power Source - Miller - Welding Equipment
OM-167 439HFebruary 1998ProcessesGas Tungsten Arc(TIG) WeldingShielded Metal Arc(Stick) WeldingDescriptionArc Welding Power SourceEconotigVisit our website atwww.MillerWelds.comR
From Miller to YouThank you and congratulations on choosing Miller. Nowyou can get the job done and get it done right. We knowyou don’t have time to do it any other way.That’s why when Niels Miller first started building arcwelders in 1929, he made sure his products offeredlong-lasting value and superior quality. Like you, hiscustomers couldn’t afford anything less. Miller productshad to be more than the best they could be. They had tobe the best you could buy.Today, the people that build and sell Miller products continue thetradition. They’re just as committed to providing equipment and servicethat 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 yourMiller products. Please take time to read the Safety precautions. They willhelp you protect yourself against potential hazards on the worksite. We’vemade installation and operation quick and easy.With Miller you can count on years of reliableservice with proper maintenance. And if forsome reason the unit needs repair, there’s aTroubleshooting section that will help youMiller is the first welding figure out what the problem is. The parts listequipment manufacturer in will then help you to decide which exact partthe U.S.A. to be registered tothe ISO 9001 Quality System you may need to fix the problem. Warranty andStandard.service information for your particular modelare also provided.Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller,or visit us at www.MillerWelds.com on the web.Working as hard as you do– every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.Miller offers a TechnicalManual which providesmore detailed service andparts information for yourunit. To obtain a TechnicalManual, contact your localdistributor. Your distributorcan also supply you withWelding Process Manualssuch as SMAW, GTAW,GMAW, and GMAW-P.
EconotigDescriptionPatented technology and Miller’s vast experience inpower source design come together in a truly affordable and effective TIG package. The Econotig isa full-featured machine that brings you capabilitieswhich were previously available only with heavyduty industrial TIG equipment. You get big machineperformance from a sleek, compact package.The Econotig’s unique design and Miller’s innovative engineering make a system that is incrediblyeasy to use. It’s an excellent choice for novice usersand hobbyists, but don’t underestimate thismachine’s power. It has the strength and stamina tohandle a wide variety of light industrial weldingtasks. Yet it operates off single-phase power.The Econotig is a complete AC/DC, TIG and Stickwelding package. There are no hidden costs or extras to buy. All you need is a bottle of shielding gasand some Stick electrodes and you’re ready to startwelding. It’s ideal for farmers, ranchers, hobbyistsand moonlighters – anyone who requires the versatility to handle Stick work, plus the finesse availableonly from the TIG process.Call1-800-4-A-MILLERfor your localMiller distributor.Your distributor givesyou .ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in your handsin 24 hours.SupportNeed fast answers to thetough welding questions?Contact your distributor.The expertise of thedistributor and Miller isthere to help you, everystep of the way.In the TIG mode, the Econotig offers superior performance: 18 gauge to 3/16 in (1.2 to 4.8 mm) steel andstainless steel; 14 gauge to 3/16 in (1.8 to 4.8 mm)aluminum (see Section 5.4). For thicker metals,take advantage of the Stick mode using 3/32 and 1/8in (2.4 and 3.2 mm) electrodes. No matter what levelof skill and experience you have, the Econotig willhelp you be a more effective, versatile and productive welder.RFeaturesH AC output for superior aluminum weldingH DC output for mild and stainless steelH Four-position polarity and range selectorswitch offers two AC current ranges, DCelectrode (–) for TIG, and DC electrode ( ) forStickH Patented, built-in arc assist stabilizer for ACTIG on aluminumH Patented, built-in arc assist starter for DC TIGH Process switch automatically sets machinefor TIG or StickH Unique “flow-through” shielding gas TIG torchconnection allows removal of torch withouttoolsH Preset automatic postflow timer protectstungsten tip, workpiece and torchH Automatic high temperature shutdownProcessesGas Tungsten Arc(TIG) WeldingShielded Metal Arc(Stick) WeldingThe following terms are used interchangeablythroughout this manual:TIG GTAWStick SMAWTable of ContentsSectionPage1. Safety Precautions . . . . . . . . . . . . . . . . . . . .12. Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . .93. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . .114. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .125. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156. Maintenance and Troubleshooting . . . . . .187. Electrical Diagram . . . . . . . . . . . . . . . . . . . . .198. High Frequency . . . . . . . . . . . . . . . . . . . . . . . .209. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Miller offers a Technical Manualwhich provides more detailedservice and parts information foryour unit. To obtain a TechnicalManual, contact your local distributor. Your distributor can alsosupply you with Welding ProcessManuals such as SMAW, GTAW,GMAW, and GMAW-P.For practical information on welding, process applications, and Millerproducts, visit our website atwww.millerwelds.comOptions and AccessoriesWarranty
Declaration of ConformityMiller Electric Mfg. Co.Manufacturer’s Name:1635 W. Spencer StreetAppleton, WI 54914 USAManufacturer’s Address:Declares that the product:ECONOTIG (product name)conforms to the following Directives and Standards:DirectivesElectromagnetic Compatibility Directives: 89/336EEC, 92/31/EECLow Voltage Directive: 73/23/EECMachinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EECStandardsElectromagnetic Compatibility (EMC) Product standard for arc welding equipment:EN50199: August 1995Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1(April 1995 – Draft revision)Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989Insulation coordination for equipment within low-voltage systems:Part 1: Principles, requirements and tests: IEC 664-1: 1992European Contact:Telephone:Fax:dec con1 7/95Mr. Luigi Vacchini, Managing DirectorMILLER Europe S.P.A.Via Privata Iseo20098 San GiulianoMilanese, Italy39(02)98290-139(02)98281-552
1. Safety Precautions – Read Before Using1.1Symbol UsageOM-167 439H - Date, safety som 4/97Means Warning! Watch Out! There are possiblehazards with this procedure! The possible hazards areshown in the adjoining symbols.YMarks a special safety message.Means “Note”; not safety related.1.2This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessaryactions to avoid the hazards.Arc Welding HazardsYThe symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1.4. Read andfollow all Safety Standards.YOnly qualified persons should install, operate, maintain, andrepair this unit.YDuring operation, keep everybody, especially children, away.D Do not drape cables over your body.D If earth grounding of the workpiece is required, ground it directlywith a separate cable – do not use work clamp or work cable.D Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.D Use only well-maintained equipment. Repair or replace damagedparts 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 workpieceor worktable as near the weld as practical.ELECTRIC SHOCK can kill.Touching live electrical parts can cause fatalshocks or severe burns. The electrode and workcircuit is electrically live whenever the output is on.The input power circuit and machine internalcircuits are also live when power is on. In semiautomatic orautomatic wire welding, the wire, wire reel, drive roll housing, and allmetal parts touching the welding wire are electrically live. Incorrectlyinstalled or improperly grounded equipment is a hazard.D Do not touch live electrical parts.D Insulate work clamp when not connected to workpiece to preventcontact with any metal object.SIGNIFICANT DC VOLTAGE exists after removal ofinput power on inverters.D Turn Off inverter, disconnect input power, and discharge inputcapacitors according to instructions in Maintenance Sectionbefore touching any parts.D Wear dry, hole-free insulating gloves and body protection.FUMES AND GASES can be hazardous.D Insulate yourself from work and ground using dry insulating matsor covers big enough to prevent any physical contact with thework or ground.Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.D Do not use AC output in damp areas, if movement is confined, or ifthere 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 onunit.D Keep your head out of the fumes. Do not breathe the fumes.D If inside, ventilate the area and/or use exhaust at the arc toremove welding fumes and gases.D If ventilation is poor, use an approved air-supplied respirator.D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power accordingto OSHA 29 CFR 1910.147 (see Safety Standards).D Read the Material Safety Data Sheets (MSDSs) and themanufacturer’s instructions for metals, consumables, coatings,cleaners, and degreasers.D Properly install and ground this equipment according to itsOwner’s Manual and national, state, and local codes.D Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure thebreathing air is safe.D Always verify the supply ground – check and be sure that inputpower cord ground wire is properly connected to ground terminalin disconnect box or that cord plug is connected to a properlygrounded receptacle outlet.D When making input connections, attach proper groundingconductor first – double-check connections.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.OM-167 439D Do not weld in locations near degreasing, cleaning, or sprayingoperations. The heat and rays of the arc can react with vapors toform highly toxic and irritating gases.D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from theweld area, the area is well ventilated, and if necessary, whilewearing an air-supplied respirator. The coatings and any metalscontaining these elements can give off toxic fumes if welded.1
ARC RAYS can burn eyes and skin.Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.D Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes when welding or watching (see ANSI Z49.1and Z87.1 listed in Safety Standards).D Wear approved safety glasses with side shields under yourhelmet.D Use protective screens or barriers to protect others from flash andglare; warn others not to watch the arc.BUILDUP OF GAS can injure or kill.D Shut off shielding gas supply when not in use.D Always ventilate confined spaces or useapproved air-supplied respirator.HOT PARTS can cause severe burns.D Do not touch hot parts bare handed.D Allow cooling period before working on gun ortorch.D Wear protective clothing made from durable, flame-resistantmaterial (leather and wool) and foot protection.MAGNETIC FIELDS can affect pacemakers.WELDING can cause fire or explosion.Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks,hot workpiece, and hot equipment can cause firesand burns. Accidental contact of electrode to metal objects cancause sparks, explosion, overheating, or fire. Check and be sure thearea is safe before doing any welding.D Protect yourself and others from flying sparks and hot metal.D Do not weld where flying sparks can strike flammable material.D Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.D Be alert that welding sparks and hot materials from welding caneasily go through small cracks and openings to adjacent areas.D Watch for fire, and keep a fire extinguisher nearby.D Pacemaker wearers keep away.D Wearers should consult their doctor beforegoing near arc welding, gouging, or spotwelding operations.NOISE can damage hearing.Noise from some processes or equipment candamage hearing.D Wear approved ear protection if noise level ishigh.D Be aware that welding on a ceiling, floor, bulkhead, or partitioncan cause fire on the hidden side.CYLINDERS can explode if damaged.D Do not weld on closed containers such as tanks, drums, or pipes,unless they are properly prepared according to AWS F4.1 (seeSafety Standards).Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode.Since gas cylinders are normally part of the weldingprocess, be sure to treat them carefully.D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock and fire hazards.D Protect compressed gas cylinders from excessive heat,mechanical shocks, slag, open flames, sparks, and arcs.D Do not use welder to thaw frozen pipes.D Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.D Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.D Keep cylinders away from any welding or other electrical circuits.D Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.D Never drape a welding torch over a gas cylinder.D Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.D Never weld on a pressurized cylinder – explosion will result.FLYING METAL can injure eyes.D Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.D Wear approved safety glasses with sideshields even under your welding helmet.2D Never allow a welding electrode to touch any cylinder.D Use only correct shielding gas cylinders, regulators, hoses, andfittings designed for the specific application; maintain them andassociated 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 inuse or connected for use.D Read and follow instructions on compressed gas cylinders,associated equipment, and CGA publication P-1 listed in SafetyStandards.OM-167 439
1.3Additional Symbols for Installation, Operation, and MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or nearcombustible surfaces.D Do not install unit near flammables.MOVING PARTS can cause injury.D Keep away from moving parts such as fans.D Keep all doors, panels, covers, and guardsclosed and securely in place.D Do not overload building wiring – be sure power supply systemis properly sized, rated, and protected to handle this unit.FALLING UNIT can cause injury.D Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.D Use equipment of adequate capacity to lift andsupport unit.D If using lift forks to move unit, be sure forks arelong enough to extend beyond opposite side ofunit.OVERUSE can cause OVERHEATINGD Allow cooling period; follow rated duty cycle.D Reduce current or reduce duty cycle beforestarting to weld again.D Do not block or filter airflow to unit.H.F. RADIATION can cause interference.D High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.D Have only qualified persons familiar withelectronic equipment perform this installation.D The user is responsible for having a qualified electricianpromptly correct any interference problem resulting from theinstallation.D If notified by the FCC about interference, stop using theequipment 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 andshielding to minimize the possibility of interference.STATIC (ESD) can damage PC boards.D Put on grounded wrist strap BEFOREhandling boards or parts.D Use proper static-proof bags and boxes tostore, move, or ship PC boards.MOVING PARTS can cause injury.D Keep away from moving parts.D Keep away from pinch points such as driverolls.ARC WELDING can cause interference.D Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.D Be sure all equipment in the welding area iselectromagnetically compatible.D To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.D Locate welding operation 100 meters from any sensitive electronic equipment.WELDING WIRE can cause injury.D Do not press gun trigger until instructed to doso.D Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.1.4D Be sure this welding machine is installed and groundedaccording to this manual.D If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.Principal Safety StandardsSafety in Welding and Cutting, ANSI Standard Z49.1, from AmericanWelding Society, 550 N.W. LeJeune Rd, Miami FL 33126Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington,D.C. 20402.Recommended Safe Practices for the Preparation for Welding andCutting of Containers That Have Held Hazardous Substances,American Welding Society Standard AWS F4.1, from AmericanWelding Society, 550 N.W. LeJeune Rd, Miami, FL 33126National Electrical Code, NFPA Standard 70, from National FireProtection Association, Batterymarch Park, Quincy, MA 02269.OM-167 439Safe Handling of Compressed Gases in Cylinders, CGA PamphletP-1, from Compressed Gas Association, 1235 Jefferson DavisHighway, Suite 501, Arlington, VA 22202.Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale,
Arc Welding Power Source. 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 cat
the welding processes most often used in today's industry including plasma arc cutting, oxyfuel gas cutting and welding, Gas Metal Arc Welding (GMAW), Flux-Cored Arc Welding (FCAW), Shielded Metal Arc Welding (SMAW), and Gas Tungsten Arc Welding (GTAW). Flat welding positions and basic joints will be practiced. Pipe and tube welding
HMP presents a wide range of AR -200 or MMA-200 of 200 AMP single phase inverter welding machine. These ARC Welding machines are available in various model ranges. HMP have a wide range of 200A ARC inverter welding machine with all standard accessories. HMP have 200A models of Welding as ARC-200N, ARC-200G, ARC-200MOS, ARC-200L, ARC-
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Apr 30, 2008 · Carbon Arc Cutting/PACCarbon Arc Cutting/PAC 16 16 Hardfacing 10 Wee d g ( ot de ed & ed)lding (not defined & mixed) 21 . GTAW Gas-Tungsten Arc Welding (TIG) GMAW Gas-Metal Arc Welding (MIG) SMAW Shielded Metal Arc Welding (Stick or Manual Arc Welding) FCAW Flux Core Arc Welding. Step 2: Filler Metal/Base Metal .
Precautions and safe practices outlined in this booklet cover arc welding and cutting processes such as the following: 1. Gas metal arc welding (GMAW), commonly known as “MIG” welding 2. Gas tungsten arc welding (GTAW), commonly referred to as “TIG” welding 3. Shielded metal arc welding (S
Arc Welding Overview All arc welding uses an electric arc to produce a weld by melting the base material and filler metal, if applicable Three main differences between arc welding processes: How the welding arc is initiated and
Shielded Metal-Arc Welding Shielded metal-arc welding is the most common welding process used on Ductile Iron Pipe in the field. The equipment necessary for shielded metal-arc welding is as follows: 1. D.C. arc welder using reversed polarity. 2.Suitable welding electrodes. 3.Welding cable, work-piece cable, electrode holder,
Units of Study by Grade Level Kindergarten 5 Grade 1 15 Grade 2 25 Grade 3 35 Grade 4 45 Grade 5 54 Grade 6 64 Differentiation Guide 72 Curriculum Connections 75 Pacing Guide 78 . 3 Rationale and Philosophy Note on Curriculum Format The Chesterfield School District has adopted the Understanding by Design (UbD) format to organize the Curriculum Standards. Overall Unit topics are thus seen as .
