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Miller Electric 152 manual

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Table of contents for the manual

  • Page 1

    Processes Description TIG (GT A W ) W elding Arc Welding Power Source OM-206 141 754F October 1999 Stick (SMA W) W elding 152 Model 175 Model Maxstar 152 And 175 R Visit our website at www.MillerWelds.com[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

    The following terms are used interchangeably throughout this manual: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-206 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Watch O[...]

  • Page 6

    OM-206 Page 2 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. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87[...]

  • Page 7

    OM-206 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. F A[...]

  • Page 8

    OM-206 Page 4 1-5. EMF Information Considerations About Welding And The Ef fects Of Low Frequency Electric A n d M a g n e t i c F i e l d s W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 1[...]

  • Page 9

    OM-206 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulier . [...]

  • Page 10

    OM-206 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans le[...]

  • Page 11

    OM-206 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharger l[...]

  • Page 12

    OM-206 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for the[...]

  • Page 13

    OM-206 Page 9 SECTION 2 – SPECIFICA TIONS Unless otherwise noted, the 175 model is shown throughout this manual. NOTE 2-1. Specifications Model Rated Welding Output Amperage Range Maximum Open-Circuit V oltage DC Amperes Input at Rated Load Output KV A KW W eight Overall Dimensions 152 120 A @ 25 V olts DC, 100% Duty Cycle 1 – 150 95 230 V olts[...]

  • Page 14

    OM-206 Page 10 2-3. Duty Cycle And Overheating rduty1 5/95 – SB-121 591-B / SB-144 507-B / ST-157 356-B Duty Cycle is percentage of 10 mi n- utes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit and void warranty . 0 15 minutes When overheated, thermostat opens, output stops, and cooling fan keeps runni[...]

  • Page 15

    OM-206 Page 1 1 SECTION 3 – INST ALLA TION 1 10 in (254 mm) Open Space On Right Side And Rear Of Unit For Good Airflow 2 Lifting Handle Use handle to move unit. 3 Rating Label Locate unit near correct input power supply . Right Rear 1 3-1. Selecting A Location Ref. SA-145 666-C 2 3 1 W eld Output Cable Determine to t a l c a b l e l e n g t h i n[...]

  • Page 16

    OM-206 Page 12 1 Positive (+) Weld Output Receptacle 2 Negative ( – ) W eld Output Receptacle 3 Connector For Electrode Positive (DCEP), connect work cable connector to negative ( – ) receptacle and elec- trode holder cable connector to positive (+) receptacle. For Electrode Negative (DCEN), reverse cable connections. Align keyway , insert conn[...]

  • Page 17

    OM-206 Page 13 3-6. Remote 14 Socket Information A +15 volts dc. B Contact closure to A completes +15 volts dc contactor control circuit. C Output command reference; 0 to +10 volts dc depending on setting of Amperage Adjustment control R4. D Remote control circuit common. E Input command signal (potentiometer wiper or 0 to +10 volts dc). K Chassis [...]

  • Page 18

    OM-206 Page 14 Have only qualified persons make this installation. 1 Line Disconnect Device Of Proper Rating 2 Input Conductors 3 Grounding Conductor Select size and length using Sec- tion 3-10. Conductor rating must comply with national, state, and local electrical codes. Strip 3/8 in (10 mm) insulation of f conductors. 4 Strain Relief Connector R[...]

  • Page 19

    OM-206 Page 15 SECTION 4 – OPERA TION ST-152 127-A 1 Amperage Adjustment Control 2 Amperage Control Switch 3 Output (Contactor) Switch 4 Lift-Arc Switch 5 W eld Process Switch 6 Power Switch 7 Pilot Light 1 2 34 5 6 7 4-1. Controls 1 Output (Contactor) Switch Us e sw itch to select way of control- ling output. Fo r front panel control, place swit[...]

  • Page 20

    OM-206 Page 16 ST-159 059 / S-0769 1 Amperage Adjustment Control Use control to select weld amper- age. Amperage may be adjusted while welding. 2 Amperage Control Switch Use switch to select way of control- ling amperage adjustment. Fo r front panel control, place switch in Panel position. For remote control, place switch in Remote 14 position (see[...]

  • Page 21

    OM-206 Page 17 Lift-Arc switch must be in Off position when using a High-Frequency unit with this welding power source, or when using the SMAW welding process. NOTE 1 Lift-Arc Switch Use switch to select Lift-Arc On or Of f. With Lift-Arc On, start an arc in GT AW welding as follows: 2 GT AW Electrode 3 W orkpiece T ouch tungsten electrode to work-[...]

  • Page 22

    OM-206 Page 18 SECTION 5 – MAINTENANCE & TROUBLESHOOTING T urn Off all power before maintaining. 3 Months OR Blow O u t Or V acuum Inside Replace Unreadable Labels 6 Months T ape Or Replace Cracked Cables ST-145 666-C Clean And T ighten W eld Connections 3 Months 14-Pin Cord Gas Hose T orch Cable Replace Cracked Parts See Section 8 3-2 – ?[...]

  • Page 23

    OM-206 Page 19 ST-153 136-B Turn Of f welding power source and disconnect input power . Remove wrapper . 1 Input Capacitor C1 (Both Models) 2 Input Capacitor C2 (175 Models Only) 3 V oltmeter Check input capacitor(s). Measure the dc voltage across th e positive (+) and negative ( – ) terminals until voltage drops to near 0 (zero) volts. Proceed w[...]

  • Page 24

    OM-206 Page 20 5-3. T roubleshooting T rouble Remedy No weld output; unit completely inop- erative. Be sure Power switch is On (see Section 4-6). Secure power cord plug in receptacle (152 model) (see Section 3-7). Be sure line disconnect switch is On (see Section 3-9). Check line fuse(s) and replace if necessary . Reset circuit breakers (see Sectio[...]

  • Page 25

    OM-206 Page 21 Notes[...]

  • Page 26

    OM-206 Page 22 SECTION 6 – ELECTRICAL DIAGRAMS SC-166 403 Figure 6-1. Circuit Diagram For 152 Model[...]

  • Page 27

    OM-206 Page 23 SC-170 697 Figure 6-2. Circuit Diagram For 175 Model[...]

  • Page 28

    OM-206 Page 24 SECTION 7 – SELECTING AND PREP ARING TUNGSTEN ELECTRODE gtaw 7/97 For additional information, see your distributor for a handbook on the Gas T ungsten Ar c Welding (GT AW) pr ocess.Wear clean gloves to prevent contamination of tungsten electrode. NOTE 7-1. Selecting T ungsten Electrode Amperage Range - Gas T ype ♦ - Polarity Elec[...]

  • Page 29

    OM-206 Page 25 7-2. Preparing T ungsten For AC Or DC Electrode Positive (DCEP) Welding Ref. S-0161 1 T ungsten Electrode 2 Balled End Y Understand and follow safety symbols at start of Section 8-1 before preparing tungsten. Ball end of tungsten before welding by applying either an ac amperage slightly higher than what is recom- mended for a given e[...]

  • Page 30

    OM-206 Page 26 SECTION 8 – GUIDELINES FOR TIG WELDING (GT A W) 8-1. Positioining The T orch ST-161 892 Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl a c e w o r k c l amp as close t o the weld as possible. 1 W orkpiece Make sure workpiece is clean before welding. 2 W ork Cl[...]

  • Page 31

    OM-206 Page 27 8-3. Positioning T orch T ungsten For V arious W eld Joints ST-162 003 / S-0792 70 ° 70 ° 90 ° 20 ° 20 ° 10 ° 20 ° 70 ° 40 ° 30 ° 20 ° 70 ° 90 ° 20 ° Butt Weld And Stringer Bead “ T ” Joint Lap Joint Corner Joint[...]

  • Page 32

    OM-206 Page 28 SECTION 9 – P ARTS LIST Figure 9-1. Main Assembly (175 Model Illustrated) ST-145 668-J . Hardware is common and not available unless listed. . *18 Is Supplied with 152 Model only *[...]

  • Page 33

    OM-206 Page 29 152 175 Quantity Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Model 1 195 585 HANDLE, rubberized carrying 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 134 327 LABEL, warning general precautionary 1 1 . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 34

    OM-206 Page 30 152 175 Quantity Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly (Continued) Model PLG1 1 1 15 094 CONNECTOR & SOCKETS, (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 13 746 CONNECTOR, rect skt 24-18ga Molex 39-00-0038 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 35

    OM-206 Page 31 152 175 Quantity Description Part No. Dia. Mkgs. Item No. Figure 9-2. Module, Power & Diode (Fig 9-1 Item 26 & 27) Model 1 C1 1 093 085 CAP ACITOR, polye MF .0047uf 1000V 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 158 540 MODULE, pwr (consisting of) 1 . . . . . . . . . . . . . . . . [...]

  • Page 36

    OM-206 Page 32 152 175 Quantity Description Part No. Dia. Mkgs. Item No. Figure 9-2. Module, Power & Diode (Fig 9-1 Item 26 & 27) (Continued) Model 16 R10 030 839 RESIST OR, WW fxd 5W 220 ohm 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DM1 151 479 MODULE, diode (consisting of) 1 . . . . . . .[...]

  • Page 37

    Notes[...]

  • Page 38

    [...]

  • Page 39

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y ou r distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise [...]

  • Page 40

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada F A X : 920-735-4134 Int ernati onal FAX: 920-735-4125 European Headquarters – United[...]