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Miller Electric HF-251D-1 manual

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Table of contents for the manual

  • Page 1

    HF-251D-1 And HF-251-2 Processes Description TIG (GT A W ) W elding OM-611 096 556U January 2004 High Frequency Arc Starter 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

    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

    [...]

  • Page 5

    OM-61 1 Page 1 Return T o T able Of Contents SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 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 sym[...]

  • Page 6

    OM-61 1 Page 2 Return T o T able Of Contents Arc rays from the welding 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 a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or [...]

  • Page 7

    OM-61 1 Page 3 Return T o T able Of Contents 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 pro[...]

  • Page 8

    OM-61 1 Page 4 Return T o T able Of Contents 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www .aws.org). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Contain[...]

  • Page 9

    OM-61 1 Page 5 Revenez à la table des matières 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 sécurit[...]

  • Page 10

    OM-61 1 Page 6 Revenez à la table des matières 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 c au - ser des brûlures oculaires et cuta- n?[...]

  • Page 11

    OM-61 1 Page 7 Revenez à la table des matières 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 produ[...]

  • Page 12

    OM-61 1 Page 8 Revenez à la table des matières 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 an[...]

  • Page 13

    OM-61 1 Page 9 Return T o T able Of Contents SECTION 3 − INST ALLA TION 3-1. Specifications W elding Circuit Rat- Input Powe r Cord With T ype Of Input Power Dimensions W eight Circuit Rat- ing Cord With Plug 1 15 V olts 230 V olts Height Width Length 1 15 V olts 230 V olts 250 Amperes At 60% Duty Cycle 10 ft (3 m) 1 15 V olts AC Single-Phase 50/[...]

  • Page 14

    OM-61 1 Page 10 Return T o T able Of Contents Obtain gas cylinder and chain to running gear , wall, or other station- ary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove c ap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter I[...]

  • Page 15

    OM-61 1 Page 1 1 Return T o T able Of Contents The supplied cord with plugs is for use with CC or CC/CV welding power sources having the proper , matching 14-pin receptacle. Do not use cordset on machines without the 14-pin receptacle. NOTE 159 645-A / Ref. S-0004-A / S-0283-A Y T ur n Off HF Unit and welding power source, and discon- nect input po[...]

  • Page 16

    OM-61 1 Page 12 Return T o T able Of Contents sb7.1 5/94 − Ref. 098 957-D / Ref. S-0004-A / S-0750 / Ref. 141 127-B 1 Operator Control Receptacle RC1 (See Section 3-6) 2 Keyway 3 Plug 4 Threaded Collar T o connect to receptacle, align keyway , insert plug, and tighten threaded collar . 3 4 OR AJ B K I C L NH D M G E F 12 The 14-socket Operator Co[...]

  • Page 17

    OM-61 1 Page 13 Return T o T able Of Contents Y T urn Off HF Unit and welding power source, and discon- nect input power before making connections. Stop engine on welding genera- tors. Y Not connecting work cables to HF Unit will damage power source. Always connect work cables to W ork Input/ Output terminal. 1 Electrode In T erminal Open left side[...]

  • Page 18

    OM-61 1 Page 14 Return T o T able Of Contents Ref. 159 606-B / Ref. 149 354-A Y Read and follow entire Sec- tion 8 about HF equipment be- fore i n s t a l l i n g u n i t . Y Direct Current (DC) will dam- age HF Unit. Connect unit only to Alternating Current (AC) supply . Do not cut grounding terminal off plug. 1 Grounded Receptacle See Section 3-1[...]

  • Page 19

    OM-61 1 Page 15 Return T o T able Of Contents SECTION 4 − OPERA TION Ref. 098 956-D 1 Power Switch 2 Pilot Light 3 High Frequency Selector Switch 4 High Frequency Switch 5 High Frequency Intensity Control 4 5 12 3 4-1. Controls Ref. 139 573 1 High Frequency Switch Start − provides HF for arc starting only . Of f − provides no HF . Use Off for[...]

  • Page 20

    OM-61 1 Page 16 Return T o T able Of Contents 1 High Frequency Intensity Control Use control to change amount of HF energy used to start and/or maintain the arc. Set as low as practical to prevent interfering with electronic equipment. 1 4-4. High Frequency Intensity Control 1 Power Switch Use switch to turn unit On and Off. 2 Pilot Light 1 2 4-5. [...]

  • Page 21

    OM-61 1 Page 17 Return T o T able Of Contents SECTION 5 − MAINTENANCE & TROUBLESHOOTING Disconnect all power before maintaining. 3 Months OR Blow O u t Or V acuum Inside Clean And T ighten W eld T erminals Replace Unreadable Labels 6 Months 14-Pin Cord Gas Hose T orch Cable Replace Cracked Parts Adjust Spark Gaps 3 Months T ape Or Replace Cra[...]

  • Page 22

    OM-61 1 Page 18 Return T o T able Of Contents Ref. 098 956-G T urn Of f unit and welding power source and disconnect input power . Loosen screw on spark gap access door and open. 1 Tungsten End Of Point Do not clean or dress tungsten. Replace point if tungsten end disappears. 2 Spark Gap Normal spark gap is 0.008 in (0.203 mm). If spark gaps are ok[...]

  • Page 23

    OM-61 1 Page 19 Return T o T able Of Contents 5-3. T roubleshooting T rouble Remedy Unit completely inoperative; Pilot light Of f. Secure input power cord plug in receptacle (see Section 3-8 ). Place Power switch in the On position (see Section 4-5). Lack of high-frequency; difficulty in es- tablishing an arc. Place High Frequency Selector Switch i[...]

  • Page 24

    OM-61 1 Page 20 Return T o T able Of Contents SECTION 6 − ELECTRICAL DIAGRAMS 130 555-D Figure 6-1. Circuit Diagram For 1 15 V olts Model[...]

  • Page 25

    OM-61 1 Page 21 Return T o T able Of Contents 140 903-E Figure 6-2. Circuit Diagram For 230 V olts Model[...]

  • Page 26

    OM-61 1 Page 22 Return T o T able Of Contents SECTION 7 − HIGH FREQUENCY 7-1. Welding Processes Requiring High Frequency high_freq 12/96 − S-0693 1 High-Frequency V oltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. 1 TIG Work 7-2. Incorrect Installation 50 ft (15 m) S-0694 Sources of Direct High-Freque[...]

  • Page 27

    OM-61 1 Page 23 Return T o T able Of Contents 7-3. Correct Installation 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case, work output terminal, line disconnect device, input supply , and worktable. 2 Center Point of Welding Zone Midpoint between high-frequency source and welding torch. 3 [...]

  • Page 28

    OM-61 1 Page 24 Return T o T able Of Contents SECTION 8 − SELECTING AND PREP ARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING ac/dc_gtaw 2/2004 Y Whenever possible and practical, use DC weld output instead of AC weld output. 8-1. Selecting T ungsten Electrode ( Wear Clean gloves T o Prevent Contamination Of T ungsten ) Amperage Range - Gas T ype ♦[...]

  • Page 29

    OM-61 1 Page 25 Return T o T able Of Contents 8-2. Preparing T ungsten Electrode For W elding Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator . Read MSDS for safety infor- mation. Consider using tungsten con[...]

  • Page 30

    OM-61 1 Page 26 Return T o T able Of Contents 9 -2. T orch Movement During Welding 162 002-B T ungsten Without Filler Rod T ungsten With Filler Rod Form pool T ilt torch Move torch to front of pool. Repeat process. 75 ° 75 ° W elding direction Form pool Tilt torch Add filler metal Move torch to front of pool. Repeat process. Remove rod W elding d[...]

  • Page 31

    OM-61 1 Page 27 Return T o T able Of Contents Notes[...]

  • Page 32

    OM-61 1 Page 28 Return T o T able Of Contents SECTION 10 − P ARTS LIST Figure 10-1. Complete Assembly (Part 1 of 2) (115V Model) 098 955-L Part 1 of 2 . Hardware is common and not available unless listed. 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 19 20 21 22 23 18 24 25 26 27 28 29 30 31 32 12 33 34 35 14 36[...]

  • Page 33

    OM-61 1 Page 29 Return T o T able Of Contents 1 15V Description Part No. Dia. Mkgs. Item No. Figure 10-1. Complete Assembly (Part 1 of 2) Model Quantity 230V 2 206 108 SADDLE CLAMP ASSY 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 +129 366 WRAPPER 1 1 . . . . . . . . . . . .[...]

  • Page 34

    OM-61 1 Page 30 Return T o T able Of Contents 098 955-L Part 2 of 2 . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 7 9 10 16 17 18 19 20 25 21 22 24 25 26 27 23 15 13 14 12 Figure 10-2. Complete Assembly (Part 2 of 2) (115V Model)[...]

  • Page 35

    OM-61 1 Page 31 Return T o T able Of Contents 1 15V Description Part No. Dia. Mkgs. Item No. Figure 10-2. Complete Assembly (Part 2 of 2) Model Quantity 230V 1 SR3 035 704 RECTIFIER, integ 40A 800V 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C14 031 630 CAP ACITOR, elctlt 22uf 50VDC 1 . . . . . . . . . [...]

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  • Page 39

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 8/03 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  2004 Miller Electric Mfg. Co. 1/04 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Com pany 1635 W es t Spenc er S treet Applet on, W I 5 4914 USA International He adquarte rs− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F AX: 920-735-4134 Int ernational F A X: 920-735-4125 European Headqua rt ers − U[...]