Beruflich Dokumente
Kultur Dokumente
November 2004
Processes
Stick (SMAW) Welding
Description
SRH-500
Mil_Thank 7/03
TABLE OF CONTENTS
Directives
Standards
Telephone: 39(02)98290-1
Fax: 39(02)98290-203
dec_con1_11/02
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means Note; not safety related. to avoid the hazards.
Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
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 Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Use protective screens or barriers to protect others from flash and D Allow cooling period before working on gun or
glare; warn others not to watch the arc. torch.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion. D Pacemaker wearers keep away.
D Wearers should consult their doctor before
Welding on closed containers, such as tanks, going near arc welding, gouging, or spot
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot welding operations.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding. NOISE can damage hearing.
D Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
D Do not weld where flying sparks can strike flammable material. damage hearing.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Wear approved ear protection if noise level is
high.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can CYLINDERS can explode if damaged.
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
unless they are properly prepared according to AWS F4.1 (see
gas cylinders are normally part of the welding
Safety Standards). process, be sure to treat them carefully.
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly D Protect compressed gas cylinders from excessive heat, mechani-
unknown paths and causing electric shock and fire hazards. cal 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 stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact 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, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap. D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches, D Never weld on a pressurized cylinder explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D Turn face away from valve outlet when opening cylinder valve.
D Welding, chipping, wire brushing, and grinding D Keep protective cap in place over valve except when cylinder is in
cause sparks and flying metal. As welds cool, use or connected for use.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and CGA publication P-1 listed in Safety
shields even under your welding helmet. Standards.
S-176 254-A
points and procedures.
? A 7 Move jumper links as shown
5
on inside label to match
voltage at job site.
3 8 Having a loop of extra length,
connect grounding conductor
4 first.
S-179 290 9 Connect line input conductors
as shown on inside label
double-check all connections,
jumper link positions, and
input voltage before applying
5 6 7 8 9 power.
A Amperes
Voltage Control/
Panel
Percent
Protective Earth
(Ground)
A A Negative () A B Negative ()
Negative Weld
Weld Output Termi- Weld Output Termi- Input
45-250A 60-550A Output Terminal
nal (Low Range) nal (High Range)
U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2 Conventional
Load Voltage
Line Connection
Three-Phase
I1 Primary Current
I2 Rated Welding
Current X Duty Cycle Transformer
Rectifier
IP Degree Of
Protection
Alternating
Current
Overheating
0 V
15
OR
Minutes Reduce Duty Cycle duty1 4/95 / 201 171
18 in
(460 mm) Ref. ST-800 402-A / ST-139 445-E
Inches Millimeters
A 30-1/4 768
B 22-1/2 571
A
G C 35-3/4 908
H
C D 20 508
B F
E
E 1-1/4 32
F 1-1/2 38
G 4-1/2 114
H 29-3/4 755
Weight
J 784 lb (356 Kg)
ST-800 039
4-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.
10 ft (3 m)
Tools Needed:
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for
the mm2 equivalent weld cable sizes. S-0007-E
3/4 in
L1 L2 L3 L1 L2 L3 L1 L2 L3
S-021 148-A
3 2 1
4 5
Ref. 199 367-B
In Example:
Range Selected = 45 to 250 A DC
Maximum Amperage Selected = 100 A DC
Min = 45 A DC
Max = 100 A DC
2
3 Months
6 Months
Sealed
Blow out or vacuum inside. Bearings
During heavy service, clean Or No Oil
monthly Needed
Trouble Remedy
No weld output; unit completely Place line disconnect switch in On position (see Section 4-12B).
inoperative.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12B).
No weld output. Clean and tighten all weld connections (see Section 6-1).
Unit provides only low or minimum Check for proper line voltage.
weld output.
Check for open line fuse(s), and replace if necessary. Check and replace circuit breakers (see Sec-
tion 4-12B).
Low weld amperage; Amperage Ad- Reset circuit breaker CB1, if necessary (see Section 6-2).
justment does not control amperage.
Maximum weld output. Have Factory Authorized Service Agent check Amperage Adjustment control.
Erratic or improper weld output. Check for proper input power connections.
Excessive line current or line fuse(s) Check for proper input power connections (see Section 4-12B).
open repeatedly.
Check for proper jumper link position (see Section 4-12A).
Fan not operating and/or over heating. Check for and remove anything blocking fan movement.
086 018-D
11
10
8
7
5
6
12
1
2
803 701-A
13
+One grommet (center) is included with the Amplifier, Transformer, Stabilizer Assembly.
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
3
. Hardware is common and not 2 4
available unless listed. 1
6
8
11
10 9
13
14
11 ST-802 928
4
3
ST-018 370-D
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Call LIMITED WARRANTY Subject to the terms and conditions * Induction Heating Coils and Blankets
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
for your local the effective date of this limited warranty is free of defects in * Remote Controls
material and workmanship at the time it is shipped by Miller.
Miller distributor. * Accessory Kits
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
Your distributor also gives replace any warranted parts or components that fail due to such
* Canvas Covers
you ... defects in material or workmanship. Miller must be notified in Millers True Blue Limited Warranty shall not apply to:
Service writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings,
reliable response you relays or parts that fail due to normal wear. (Exception:
need. Most replacement Miller shall honor warranty claims on warranted equipment brushes, slip rings, and relays are covered on Bobcat,
parts can be in your listed below in the event of such a failure within the warranty Trailblazer, and Legend models.)
time periods. All warranty time periods start on the date that the
hands in 24 hours. equipment was delivered to the original retail purchaser, or one 2. Items furnished by Miller, but manufactured by others,
Support year after the equipment is sent to a North American distributor such as engines or trade accessories. These items are
Need fast answers to the or eighteen months after the equipment is sent to an covered by the manufacturers warranty, if any.
International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
Contact your distributor. 1. 5 Years Parts 3 Years Labor Miller, or equipment that has been improperly installed,
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
distributor and Miller is standards, or equipment which has not had reasonable
* Inverters (input and output rectifiers only) and necessary maintenance, or equipment which has
there to help you, every
step of the way. 2. 3 Years Parts and Labor been used for operation outside of the specifications for the
equipment.
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Semi-Automatic and Automatic Wire Feeders PERSONS TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated) In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Millers option: (1) repair; or (2)
* Maxstar 150 replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods at
3. 1 Year Parts and Labor Unless Specified customers risk and expense. Millers option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
* Motor Driven Guns (w/exception of Spoolmate Miller. Therefore no compensation or reimbursement for
Spoolguns) transportation costs of any kind will be allowed.
* Process Controllers TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Positioners and Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
* RFCS Foot Controls CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources and Coolers
ANY OTHER LEGAL THEORY.
* Water Coolant Systems (Non-Integrated)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Flowgauge and Flowmeter Regulators (No Labor) ANY IMPLIED WARRANTY, GUARANTY OR
* HF Units REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Maxstar 85, 140 PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Spot Welders OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Load Banks MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Arc Stud Power Sources & Arc Stud Guns PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Racks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
Models)
special or consequential damages, so the above limitation or
* Field Options exclusion may not apply to you. This warranty provides specific
(NOTE: Field options are covered under True legal rights, and other rights may be available, but may vary
Blue for the remaining warranty period of the from state to state.
product they are installed in, or for a minimum of
one year whichever is greater.) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
4. 6 Months Batteries and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
5. 90 Days Parts Warranty provides specific legal rights, and other rights may be
* MIG Guns/TIG Torches available, but may vary from province to province.
miller_warr 6/04
Owners Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturers
Transportation Department.