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Miller Electric 852 manual

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Table of contents for the manual

  • Page 1

    302, 452, 652 (60 Hz), 402, 602, 852 (50 Hz) Processes Description TIG (GT A W) W elding Stick (SMAW ) W elding OM-222 164 850AD 2007 − 03 Air Carbon Arc (CAC-A) Cutting and Gouging Flux Cored (FCA W ) W elding Arc Welding Power Source Gold Star Series R V isit our website at www.MillerWelds.com File: Stick (SMA W)[...]

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

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    dec_stat_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r .l. Phon[...]

  • Page 5

    OM-222 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 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 messag[...]

  • Page 6

    OM-222 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (s[...]

  • Page 7

    OM-222 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-222 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A WS F4[...]

  • Page 9

    OM-222 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE A V ANT UTILISA TION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier . . Signifie « NOT [...]

  • Page 10

    OM-222 Page 6 Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. LES RA YONS DE L ’ARC peuvent cau- ser des brûlures oculaires et cuta- nées. D Porter un masque de soudage mu[...]

  • Page 11

    OM-222 Page 7 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- SION D Ne pas placer l’appareil sur une surface inflam- mable, ni au − dessus ou à proximité d’elle. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcha[...]

  • Page 12

    OM-222 Page 8 2-4. Principales normes de sécurité Safety in W elding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (téléphone : (305) 443 − 9353, site Web : www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Pipi[...]

  • Page 13

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 9 SECTION 3 − DEFINITIONS 3-1. General Precautionary Label W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear dry insulating gloves. Do not touch electrode with bare hand. Do not wea[...]

  • Page 14

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 10 3-2. Input Connection Label 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Read the Owner ’s Manual before working on this machine. 5 Consult[...]

  • Page 15

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 1 1 3-5. Manufacturer ’ s Rating Labels For CE Products . Match label to one on unit. See Section 4-4.[...]

  • Page 16

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 12 3-6. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes Amperage Control/ Panel Gas Tungsten Arc W elding (GT AW) Shielded Metal Arc W elding (SMAW) T emperature Do Not Switch While W elding Arc Force (DIG) Percent Output Circuit Breaker Rem[...]

  • Page 17

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 13 SECTION 4 − INST ALLA TION 4-1. Specifications Model Rated W elding Amp Range DC Maximum Open- Circuit IP Rating Amperes Input at Rated Load Output, 50 or 60 Hz, Three-Phase Model W elding Output R ange DC Ci rcu it V oltage DC R a ti ng 200 V 230 V 380 V 400 V 440 V 460[...]

  • Page 18

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 14 4-3. V olt-Ampere Curves V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown. B. 450 Amp Model C. 650 Amp Model A. 300 Amp Model va_curve1 − 4/95 − SA-171 221 / SA-171 222[...]

  • Page 19

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 15 4-4. Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Rating Label (Non CE Models Only) Use rating label to determine input power needs. Label located unde[...]

  • Page 20

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 16 4-5. Dimensions And Weights Dimensions 300 Amp Models 450 Amp Models 650 Amp Models A 30 in (762 mm) including lift eye 30 in (762 mm) including lift eye 30 in (762 mm) including lift eye B 23 in (585 mm) 23 in (585 mm) 23 in (585 mm) C 30-1/2 in (775 mm) including strain [...]

  • Page 21

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 17 4-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 4-7. 1 15 V AC Receptacle And Supplementary Protectors Ref. ST-800 101-D Y T urn Off power before connecting to receptacle. 1 1 15 V 15 A AC Receptacle RC9 Power is shared between RC9 a nd Remote 1[...]

  • Page 22

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 18 4-8. W eld Output T erminals And Selecting Cable Sizes T otal Cable (Copper) Length In W eld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Y T urn Off power before connecting to weld output[...]

  • Page 23

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 19 4-10. Remote 14 Receptacle Information Socket Information 24 VOL TS AC A 24 volts ac. Protected by supplementary protector CB2. 24 VOL TS AC B Contact closure to A completes 24 volts ac contactor control circuit. C Command reference; 0 to +10 volts dc. REMOTE OUTPUT CONTRO[...]

  • Page 24

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 20 4-12. Electrical Service Guide 60 Hertz Models 300 Amp Model 450 Amp Model 650 Amp Model Input V oltage 200 230 460 575 200 230 460 575 230 460 575 Input Amperes At Rated Output 70 61 31 25 102 89 45 36 124 62 50 Max Recommended Standard Fuse Rating In Amperes 1 T ime-Dela[...]

  • Page 25

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 21 4-13. Placing Jumper Links Ref. ST-800 103-A Y Disconnect and lockout/tag- out input power before installing or moving jumper links. Check input voltage available at site. 1 Jumper Link Label Check label − only one is on unit. 2 Jumper Links Move jumper links to match in[...]

  • Page 26

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 22 4-14. Connecting Input Power 800 103-C / Ref. 801 1 16-A 3/8 in 3/8 in T ools Needed: Y Installation must meet all National an d Local Codes − have only quali- fied persons make this installation. Y Disconnect and lockout/tagout in- put power before connecting input cond[...]

  • Page 27

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 23 SECTION 5 − OPERA TION 5-1. Controls (Non CE Models) 1 Polarity Selector Switch (Optional On 50 Hz Models) T o change polarity on models not equipped with a Polarity Selector switch, reverse work and electrode cables at the weld output termi- nals (see Section 4-8). Y T [...]

  • Page 28

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 24 5-2. Controls (CE Models) 1 Polarity Selector Switch (Optional On 50 Hz Models) T o change polarity on models not equipped with a Polarity Selector switch, reverse work and electrode cables at the weld output termi- nals (see Section 4-8 ). Y T urn Off Power before reversi[...]

  • Page 29

    . A complete Parts List is available at www .MillerW elds.com OM-222 Page 25 6-2. Fuse F1 Ref. ST-800 101-C Y T urn Off power before open- ing rear access door . 1 Fuse F1 (See Parts List For Rating) Fuse F1 protects control transform- er from overload. If F1 opens, weld output and fan motor stops. Re- place F1. Close and secure access door . 1 T o[...]

  • Page 30

    OM-222 Page 26 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram[...]

  • Page 31

    OM-222 Page 27 218 518-A[...]

  • Page 32

    OM-222 Page 28 SECTION 8 − P ARTS LIST A complete Parts List is available on-line at www .MillerWelds.com. NOTE http://www .millerwelds.com/service/replacementparts.html Choose Genuine Select to review spare parts requirements such as filters, spark plugs, and fuses. Choose Service Parts to download complete parts listing. Notes[...]

  • Page 33

    Notes[...]

  • Page 34

    Notes[...]

  • Page 35

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 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 exp[...]

  • Page 36

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W or ks Comp any 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarte rs − USA USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX : 920-735-4134 Int ernati onal F A X: 9 20-735-4125 European Headqua rters ?[...]