OM-877 |
Form: 108 026 |
November 1995
OWNER’S
MANUAL
10KW AUXILIARY POWER BANK
Read and follow these instructions and all safety blocks carefully.
Have only trained and qualified persons install, operate, or service this unit.
Call your distributor if you do not understand the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079, Appleton, WI 54912 414-734-9821
cover 1/94 – ST-108 014-A |
1995 MILLER Electric Mfg. Co. |
PRINTED IN USA |
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.
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. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.
Working as hard as you do
– every power source from Miller is backed by the most hassle-free warranty in the business.
Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW,
GMAW, and GMAW-P.
TABLE OF CONTENTS
SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE . . . . . . . |
1 |
|
1-1. |
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1 |
1-2. |
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1 |
1-3. |
Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4 |
1-4. |
Standards Booklet Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
5 |
SECTION 2 – SAFETY PRECAUTIONS AND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
6 |
|
2-1. General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
6 |
|
2-2. Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
6 |
|
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
7 |
|
3-1. |
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
7 |
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
7 |
|
4-1. |
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
7 |
4-2. |
Interconnecting Cord Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
7 |
SECTION 5 – OPERATOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
9 |
|
5-1. 120 Volt Load/240 Volt Load Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
9 |
|
5-2. |
Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
9 |
5-3. |
Amperage Load Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
9 |
5-4. |
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
10 |
5-5. |
Hertz Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
10 |
5-6. |
Dual-Scale AC Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
10 |
SECTION 6 – SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
10 |
|
6-1. |
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
10 |
6-2. |
Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11 |
SECTION 7 – MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11 |
|
7-1. |
Inspection And Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11 |
7-2. |
Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11 |
SECTION 8 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
12 |
|
Figure 8-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
12 |
|
Figure 8-2. Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
14 |
|
Figure 8-3. Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
15 |
|
OM-877 – 11/95
SECTION 1 – SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. INTRODUCTION
We learn by experience. Learning safety through personal experience, like a child touching a hot stove is harmful, wasteful, and unwise. Let the experience of others teach you.
Safe practices developed from experience in the use of welding and cutting are described in this manual. Research, development, and field experience have evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when equipment is improperly used or maintained. The reason for the safe practices may not always be given. Some are based on common sense, others may require technical volumes to explain. It is wiser to follow the rules.
Read and understand these safe practices before attempting to install, operate, or service the equipment. Comply with these procedures as applicable to the particular equipment used and their instruction manuals, for personal safety and for the safety of others.
Failure to observe these safe practices may cause serious injury or death. When safety becomes a habit, the equipment can be used with confidence.
These safe practices are divided into two Sections: 1-General Precautions, common to arc welding and cutting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety are also available for additional and more complete procedures than those given in this manual. They are listed in the Standards Index in this manual. ANSI Z49.1 is the most complete.
The National Electrical Code, Occupational Safety and Health Administration, local industrial codes, and local inspection requirements also provide a basis for equipment installation, use, and service.
1-2. GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys, and fluxes can produce different fumes, gases, and radiation levels. In addition to the information in this manual, be sure to consult flux and electrode manufacturers Material Safety Data Sheets (MSDSs) for specific technical data and precautionary measures concerning their material.
A. Burn Prevention
Wear protective clothing-gauntlet gloves designed for use in welding, hat, and high safety-toe shoes. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag.
Wear helmet with safety goggles and glasses with side shields underneath, appropriate filter lenses or plates (protected by clear cover glass). This is a MUST for welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin burns.
Ear plugs should be worn when working on overhead or in a confined space. A hard hat should be worn when others work overhead.
Flammable hair preparations should not be used by persons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation as described in ANSI Standard Z49.1 listed in Standards Index. NEVER ventilate with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium-bear- ing and similar materials, when welded (or cut) may produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as the operator must wear an air-sup- plied respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface, the area is well ventilated and, if necessary, while wearing an air-supplied respirator.
Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator.
Gas leaks in a confined space should be avoided. Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a confined space.
Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open. Check to be sure that the space is safe before re-entering it.
Vapors from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene. DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting
OM-877 Page 1
atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag or heated material; misuse of compressed gases and cylinders; and short circuits.
BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits.
If combustibles are in area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot be moved, move combustibles at least 35 feet away out of reach of sparks and heat; or protect against ignition with suitable and snugfitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on (or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields.
Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if:
a.appreciable combustibles (including building construction) are within 35 feet
b.appreciable combustibles are further than 35 feet but can be ignited by sparks
c.openings (concealed or visible) in floors or walls within 35 feet may expose combustibles to sparks
d.combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat.
Hot work permit should be obtained before operation to ensure supervisor’s approval that adequate precautions have been taken.
After work is done, check that area is free of sparks, glowing embers, and flames.
An empty container that held combustibles, or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned as described in AWS Standard A6.0, listed 7 in Standards Index.
This includes: a thorough steam or caustic cleaning (or a solvent or water washing, depending on the combustible’s solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equip-
ment as recommended in A6.0. Waterfilling just below working level may substitute for inerting.
A container with unknown contents should be cleaned (see preceding paragraph). Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before welding or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air may contain flammable dust, gas, or liquid vapors (such as gasoline).
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in this manual, and those detailed in CGA Standard P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, listed 11 in Standards Index.
1.Pressure Regulators
Regulator relief valve is designed to protect only the regulator from overpressure; it is not intended to protect any downstream equipment. Provide such protection with one or more relief devices.
Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed.
Remove faulty regulator from service immediately for repair (first close cylinder valve). The following symptoms indicate a faulty regulator:
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise with downstream valve closed.
Faulty Gauge-if gauge pointer does not move off stop pin when pressurized, nor returns to stop pin after pressure release.
Repair. Do NOT attempt to repair. Send faulty regulators for repair to manufacturer’s designated repair center, where special techniques and tools are used by trained personnel.
2.Cylinders
Cylinders must be handled carefully to prevent leaks and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including third rails, electrical wires, or welding circuits. They can produce short circuit arcs that may lead to a serious accident. (See 1-3C.)
ICC or DOT marking must be on each cylinder. It is an assurance of safety when the cylinder is properly handled.
Identifying gas content. Use only cylinders with name of gas marked on them; do not rely on color to identify gas content. Notify supplier if unmarked. NEVER DEFACE or alter name, number, or other markings on a cylinder. It is illegal and hazardous.
Empties: Keep valves closed, replace caps securely; mark MT; keep them separate from FULLS and return promptly.
Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as a support or roller.
OM-877 Page 2
Locate or secure cylinders so they cannot be knocked over.
Passageways and work areas. Keep cylinders clear of areas where they may be struck.
Transporting cylinders. With a crane, use a secure support such as a platform or cradle. Do NOT lift cylinders off the ground by their valves or caps, or by chains, slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks, slag, and flame, etc. that may cause rupture. Do not allow contents to exceed 130° F. Cool with water spray where such exposure exists.
Protect cylinders particularly valves from bumps, falls, falling objects, and weather. Replace caps securely when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open a cylinder valve that can not be opened by hand. Notify your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Cylinder fittings should never be modified or exchanged.
3.Hose
Prohibited use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black for inert gases.
Use ferrules or clamps designed for the hose (not ordinary wire or other substitute) as a binding to connect hoses to fittings.
No copper tubing splices. Use only standard brass fittings to splice hose.
Avoid long runs to prevent kinks and abuse. Suspend hose off ground to keep it from being run over, stepped on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose connections. Immerse pressured hose in water; bubbles indicate leaks.
Repair leaky or worn hose by cutting area out and splicing (1-2D3). Do NOT tape.
4.Proper Connections
Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator. Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe with a clean lintless cloth.
Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking area, and that the regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded connections, clean and smooth seats where necessary. Tighten. If connection leaks, disassemble, clean, and retighten using properly fitting wrench.
Adapters. Use a CGA adapter (available from your supplier) between cylinder and regulator, if one is required. use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads.
Regulator outlet (or hose) connections may be identified by right hand threads for oxygen and left hand threads (with grooved hex on nut or shank) for fuel gas.
5.Pressurizing Steps:
Drain regulator of residual gas through suitable vent before opening cylinder (or manifold valve) by turning adjusting screw in (clockwise). Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization. Leave adjusting screw engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure increases slowly. When gauge is pressurized (gauge reaches regulator maximum) leave cylinder valve in following position: For oxygen, and inert gases, open fully to seal stem against possible leak. For fuel gas, open to less than one turn to permit quick emergency shutoff.
Use pressure charts (available from your supplier) for safe and efficient, recommended pressure settings on regulators.
Check for leaks on first pressurization and regularly there-after. Brush with soap solution (capfull of Ivory Liquid* or equivalent per gallon of water). Bubbles indicate leak. Clean off soapy water after test; dried soap is combustible.
E. User Responsibilities
Remove leaky or defective equipment from service immediately for repair. See User Responsibility statement in equipment manual.
F.Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or cutting operation; rope may burn.
*Trademark of Proctor & Gamble.
OM-877 Page 3
1-3. ARC WELDING
Comply with precautions in 1-1, 1-2, and this section. Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be used. The wise operator avoids unnecessary risks and protects himself and others from accidents. Precautions are described here and in standards referenced in index.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, those from gasshielded arcs are more severe and painful. DON’T GET BURNED; COMPLY WITH PRECAUTIONS.
1.Protective Clothing
Wear long-sleeve clothing (particularly for gas-shielded arc) in addition to gloves, hat, and shoes (1-2A). As necessary, use additional protective clothing such as leather jacket or sleeves, flame-proof apron, and fire-re- sistant leggings. Avoid outer garments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing. Button collar to protect chest and neck and button pockets to prevent entry of sparks.
2.Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an electric arc without protection.
Welding helmet or shield containing a filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced IMMEDIATELY. Replace clear cover plate when broken, pitted, or spattered.
Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Looking at an arc momentarily with unprotected eyes (particularly a high intensity gas-shielded arc) can cause a retinal burn that may leave a permanent dark area in the field of vision.
3.Protection of Nearby Personnel
Enclosed welding area. For production welding, a separate room or enclosed bay is best. In open areas, surround the operation with low-reflective, non-combusti- ble screens or panels. Allow for free air circulation, particularly at floor level.
Viewing the weld. Provide face shields for all persons who will be looking directly at the weld.
Others working in area. See that all persons are wearing flash goggles.
Before starting to weld, make sure that screen flaps or bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity. Do not overload arc welding equipment. It may overheat cables and cause a fire.
Loose cable connections may overheat or flash and cause a fire.
Never strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR TOUCH a wet surface when welding, without suitable protection.
To protect against shock:
Wear dry insulating gloves and body protection. Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when dampness or sweat can not be avoided. Sweat, sea water, or moisture between body and an electrically HOT part or grounded metal reduces the electrical resistance, and could enable dangerous and possibly lethal currents to flow through the body.
A voltage will exist between the electrode and any conducting object in the work circuit. Examples of conducting objects include, but are not limited to, buildings, electrical tools, work benches, welding power source cases, workpieces, etc. Never touch the electrode and any metal object unless the welding power source is off.
1.Grounding the Equipment
Arc welding equipment must be grounded according to the National Electrical Code, and the work must be grounded according to ANSI Z49.1 “Safety In Welding And Cutting.”
When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building ground. Conductors must be ade-
OM-877 Page 4
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