Miller Electric TIG 150 Owner's Manual
OWNER’S MANUAL
High Power
®
TIG 150
With Auto-Line
®
OM-221 022G
5/2006
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
Visit our website at
http://www.might-jp.com
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 3 – SPECIFICATIONS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-2. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-5. Installing Shoulder Strap, Selecting A Location, And Connecting Input Power . . . . . . . . . . . . . . . . 8
3-6. Selecting Extension Cord (Use Shortest Cord Possible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-7. Remote 6 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-2. Process Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Lift-Arc And TIG Impulse Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Set-Up Procedure For The GTAW Process And Restoring Factory Default Settings . . . . . . . . . . . . 12
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 6 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 8 – WELDING PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
WARRANTY
TABLE OF CONTENTS
Declaration of Conformity For
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit).
Manufacturer’s Name:
Miller Electric Mfg. Co.
Manufacturer’s Address:
1635 W. Spencer Street
Appleton, WI 54914 USA
Declares that the product:
MIGHT High Power TIG 150
has been developed for the Japanese market and conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standar
ds
Arc Welding Equipment – Part 10: Electromagnetic Compatibility (EMC) Requirements.
IEC 60974-10 August 2002
Arc Welding Equipment – Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees of Protection Provided by Enclosures (IP Code): IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems:
Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed 1.1
European Contact:
Mr. Danilo Fedolfi, Managing Director
ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Telephone:
39(02)98290-1
Fax:
39(02)98290-203
dec_stat_2/04
Notes:
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
1-2. Arc Welding Hazards
ELECTRIC SHOCK can kill.
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
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 to avoid the hazards.
V Marks a special safety message.
Means “Note”; not safety related.
V The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given
below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5.
Read and follow all Safety Standards.
V Only qualified persons should install, operate, maintain,and
repair this unit.
V During operation, keep everybody, especially children,
away.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on.The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding,
the wire, wire reel, drive roll housing, and all metal parts touching
the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
y Do not touch live electrical parts.
y Wear dry, hole-free insulating gloves and body protection.
y Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
y Do not use AC output in damp areas, if movement is confined, or
if there is a danger of falling.
y Use AC output ONLY if required for the welding process.
y If AC output is required, use remote output control if present on
unit.
y Disconnect input power or stop engine before installing or serv-
icing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
y Properly install and ground this equipment according to its
Owner's Manual and national, state, and local codes.
y Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
y When making input connections, attach proper grounding con-
ductor first – double-check connections.
y Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
y Turn off all equipment when not in use.
y Do not use worn, damaged, undersized, or poorly spliced cables.
y Do not drape cables over your body.
y If earth grounding of the workpiece is required, ground it directly
with a separate cable.
y Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
y Use only well-maintained equipment. Repair or replace dam-
aged parts at once. Maintain unit according to manual.
y Wear a safety harness if working above floor level.
y Keep all panels and covers securely in place.
y Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
y Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
y Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
y Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
y Keep your head out of the fumes. Do not breathe the fumes.
y If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
y If ventilation is poor, use an approved air-supplied respirator.
y Read the Material Safety Data Sheets (MSDSs) and the manu-
facturer's instructions for metals, consumables, coatings, cleaners, and degreasers.
y Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
y Do not weld in locations near degreasing, cleaning, or spraying
operations.The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
y Do not weld on coated metals, such as galvanized, lead, or cad-
mium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing
an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
OM-221 022 Page 1
ARC RAYS can burn eyes and skin.
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.
y Wear a welding helmet fitted with a proper shade of filter to pro-
tect your face and eyes when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
y Wear approved safety glasses with side shields under your hel-
met.
y Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
y Wear protective clothing made from durable, flame-resistant
material (leather and wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot 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.
y Protect yourself and others from flying sparks and hot metal.
y Do not weld where flying sparks can strike flammable material.
y Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
y Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
y Watch for fire, and keep a fire extinguisher nearby.
y Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
y Do not weld on closed containers such as tanks, drums, or
pipes, unless they are properly prepared according to AWS F4.1
(see Safety Standards).
y Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
y Do not use welder to thaw frozen pipes.
y Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
y Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
y Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
y Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
y Wear approved safety glasses with side shields
even under your welding helmet.
BUILDUP OF GAS can injure or kill.
y Shut off shielding gas supply when not in use.
y Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
y Do not touch hot parts bare handed.
y Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
y
Pacemaker wearers keep away.
y Wearers should consult their doctor before
going near arc welding, gouging, or spot welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
y Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
y Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
y Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
y Keep cylinders away from any welding or other electrical circuits.
y Never drape a welding torch over a gas cylinder.
y Never allow a welding electrode to touch any cylinder.
y Never weld on a pressurized cylinder – explosion will result.
y Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
y Turn face away from valve outlet when opening cylinder valve.
y Keep protective cap in place over valve except when cylinder is
in use or connected for use.
y Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
OM-221 022 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
1-4. California Proposition 65 Warnings
FIRE OR EXPLOSION hazard.
y Do not install or place unit on, over, or near
combustible surfaces.
y Do not install unit near flammables.
FALLING UNIT can cause injury.
y Use lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
y Use equipment of adequate capacity to lift and
support unit.
y If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
y Allow cooling period; follow rated duty cycle.
y Reduce current or reduce duty cycle before
starting to weld again.
y Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
y Put on grounded wrist strap BEFORE handling
boards or parts.
y Use proper static-proof bags and boxes to store,
move, or ship PC boards.
MOVING PARTS can cause injury.
y Keep away from moving parts.
y Keep away from pinch points such as drive rolls.
WELDING WIRE can cause injury.
y Do not press gun trigger until instructed to do
so.
y Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
y Do not overload building wiring – be sure power supply system
is properly sized, rated, and protected to handle this unit.
MOVING PARTS can cause injury.
y Keep away from moving parts such as fans.
y Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
y High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
y Have only qualified persons familiar with elec-
tronic equipment perform this installation.
ARC WELDING can cause interference.
y Electromagnetic energy can interfere with sen-
sitive electronic equipment such as computers
and computer-driven equipment such as
robots.
y Be sure all equipment in the welding area is
electromagnetically compatible.
y The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
y If notified by the FCC about interference, stop using the equip-
ment at once.
y Have the installation regularly checked and maintained.
y Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding
to minimize the possibility of interference.
y To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
y Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
y Be sure this welding machine is installed and grounded accord-
ing to this manual.
y If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
V Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
V Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
For Gasoline Engines:
V Engine exhaust contains chemicals known to the State of
California to cause cancer,birth defects, or other reproduc-
tive harm.
For Diesel Engines:
V Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
OM-221 022 Page 3
OM-221 022 Page 4
1-5. Principal Safety Standards
1-6. EMF Information
Safety in Welding, Cutting, and Allied Processes, ANSI Standard
Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami
FL 33126 (phone: 305-443-9353, website: www.aws.org).
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers and Piping, American Welding Society
Standard AWS F4.1, from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website:
www.aws.org).
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, P.O. Box 9101, 1 Battery March Park,
Quincy, MA 02269-9101 (phone: 617-770-3000, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1735 Jefferson Davis
Highway, Suite 1004, Arlington, VA 22202-4102 (phone: 703-4120900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-4636727 or in Toronto 416-747-4044, website: www. csainternational.org).
Practice For Occupational And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National
Standards Institute, 11 West 42nd Street, New York, NY 10036-8002
(phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (phone: 617-770-3000, website: www. nfpa.org and
www. sparky.org).
OSHA, Occupational Safety and Health Standards for General
Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh,
PA 15250 (there are 10 Regional Offices–phone for Region 5,
Chicago, is 312-353-2220, website: www.osha.gov).
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about
such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the
National Research Council concluded that: “The body of evidence, in
the committee’s judgment, has not demonstrated that exposure to
power-frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to
be examined. Until the final conclusions of the research are reached,
you may wish to minimize your exposure to electromagnetic fields
when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doc-
tor, then following the above procedures is recommended.
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