Miller Electric Snap Start II Owner's Manual

 OM-629 177 029C April 2000 TIG (GTAW) Welding Description High Frequency Arc Starter Visit our website at www.MillerWelds.com ...

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. 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 ...

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. Principal Safety Standards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. � Marks a special safety message. � Means “Note”; not safety related. 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. 1-2. Arc Welding Hazards � The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see th ...

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. ARC RAYS can burn eyes and skin. � 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). � Wear approved safety glasses with side shields under your helmet. � Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. � Wear protective clothing made from durable, flame-resistant mate- rial (leather and wool) ...

1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. � Do not install or place unit on, over, or near combustible surfaces. � Do not install unit near flammables. � Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cause injury. � Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. � Use equipment of adequate capacity to lift and support unit. � If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. OVERUS ...

1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- magnetic 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 cont ...

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. � Identifie un message de sécurité particulier. � Signifie NOTA ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à ...

Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. � Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regar- der (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). � Porter des protections approuvés pour les oreilles si le niveau sondre est trop é ...

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. � Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. � Ne pas installer l’appareil à proximité de produits inflammables � Ne pas surcharger l’installation électrique – s”assurer que l’alimen- tation est correctement dimensionné et protégé avant de mettre l’appareil en service. LA CHUTE DE L’APPAREIL peut blesser. � Utiliser l’anneau de levage uniquement pour sou- lever l’appareil, NON PAS les chariot, les bouteil- les de gaz ou tout a ...

1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cut- ting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 National Electrical Code, NFPA Standard 70, de la National Fire Protec- tion Association, Batterymarch Park, Quincy, MA 02269. Safe Handling of C ...

SECTION 2 – INTRODUCTION 2-1. Specifications Welding Circuit Rating Input Power Dimensions Net Weight 175 Amperes, 100% Duty Cycle 50/60 Hz, Single-Phase; 115 Volts AC, 0.5 Amperes; Or 230 Volts AC, 0.3 Amperes Height: 4-1/2 in (108 mm) Width: 9-3/4 in (248 mm) Length: 16-1/2 in (419 mm) 20 lb (9.1 kg) 2-2. Symbol Definitions A Amperage Seconds Negative Positive Gas Tungsten Arc Welding (GTAW) Panel/Local Gas Input Gas Output Output On Voltage Input Off Work Connection Read Operator’s Manual Preflow Time Postflow Time High Frequency On– Start Only Remote SECTION 3 – INSTALLATION 3-1. Typical Connections Power Cord Remote 14 Cord R ...

3-2. Shielding Gas Connections ST-800 293 / ST-801 480 1 Gas In Fitting Use to make connection to gas sup- ply. 2 Gas Out Fitting Use to make gas connection to torch. Fittings have 5/8-18 right-hand threads. 1 5/8, 1-1/8 in 2 Tools Needed: ...

3-3. Remote 14 Connections ST-800 293 / ST-145 666-C / ST-801 480 1 Remote 14 Receptacle Use to make connection to remote control device. 2 Remote 14 Plug Use to make connection to welding power source Remote 14 receptacle. OR 1 2 3-4. Remote 14 Receptacle Information Pin* Pin Information A 24 volts ac. B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I C +10 volts dc output to remote control. C L N H D Remote control circuit common. D M G E F E 0 to +10 volts dc input command signal from remote control. E K Circuit common *The remaining pins are not used. 3-5. Remote 14 Plug Information Pin* Pin Informatio ...

3-6. Weld Cable Connections ST-800 293 / ST-801 480 1 Negative (–) Input Plug Connect to negative (–) weld output receptacle on welding power source. 2 Positive (+) Input Plug Connect to positive (+) weld output receptacle on welding power source. GTAW DC Electrode Negative/ Straight Polarity (DCEN) 3 Torch (–) Receptacle 4 Work (+) Receptacle 1 2 3 4 3-7. Placing Jumper Links And Connecting Input Power Ref. ST-801 481-A / S-186 113 / ST-800 297-A Jumper links allow operation on dif- ferent input voltages and are facto- ry set for 115 volts ac. Place jumper links to match input voltage as shown. 1 Jumper Link Label 2 Input Voltage ...

3-8. Making Power Connections To A Maxstar 91 Or 152 Welding Power Source ST-801 497-B / SB-146 578-C 1 Terminal Strip TE1 2 Strain Relief Connector 3 Snap-In Blank Remove wrapper. Disconnect input power cord leads from TE1 and ground terminal on case. Remove power cord and strain re- lief connector, and install supplied snap-in blank into power cord hole. 4 Accessory Harness Recep- tacle 5 Power Supply Ground Lead 6 Other Ground Leads Locate accessory harness recep- tacle (supplied loose) with leads at- tached. Connect lead 16 to terminal F on TE1. Connect lead 17 to termi- nal E. Connect lead 42 to ground terminal on case bottom below ...

3-9. Installing Mounting Brackets 1 Notched Mounting Bracket Use existing screws from lower edge of Maxstar wrapper and upper edge of HF unit wrapper, and se- cure notched brackets as shown. 1 ST-800 295-A 1/4, 5/16 in Tools Needed: SECTION 4 – OPERATION 4-1. Controls ST-800 293 / ST-801 480 1 Preflow Time Control Sets length of time gas flows before arc starts. 2 Postflow Time Control Sets length of time gas flows after welding stops. 3 Power And HF On/Off Switch Down position: Turns unit Off. Middle position: Turns unit On with no HF. Use for scratch start GTAW or if Touch Start feature on welding power source is used. Up position: T ...

SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance � Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cables. Adjust spark gaps. Clean and tighten weld connections. Replace cracked parts. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. Or 5-2. Adjusting Spark Gap Ref. ST-801 481-A / Ref. S-0043 � Turn Off power before ad- justing spark gap. 1 Tungsten End Of Point Replace point if tungsten end dis- appears; do not clean or dress tungsten. 2 Spark Gap Normal spark gap is 0.012 in (0.3 mm). If adjustment is needed, pro- ceed as follows: 3 ...

5-3. Overload Protection Ref. ST-801 481-A � Turn Off power before checking fuse F1. 1 Fuse F1 Remove top of unit. F1 protects the primary side of transformer T1 from overload. If F1 opens, the unit no longer operates. Replace F1 if open. Be sure jumper link positions (see Section 3-7) match input voltage being used. Reinstall top before operating unit. Tools Needed: 1/4 in 1 5-4. Troubleshooting Table Trouble Remedy Unit completely inoperative. Check for proper input power connections (see Section 3-7). Be sure Power and HF On/Off switch is in a Power On position (see Section 4-1). Check fuse F1 (see Section 5-3). Lack of high frequen ...