Miller Electric Tandem Systems User manual

Millerfi
OWNERS
MANUAL
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.
''~~
__~'
~'~1~3
April
1993
Effective
With
Style
No.
JD-25
Form:
OM-1553
Tandem
Systems
U
U
U

For
help,
call
your
distributor

or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O. Box
1079,
Appleton,
WI
54912
414-734-9821
cover
8/92
-
ST
I
10
784-A
PRINTED
IN
USA

u-I.
MILLERS
TRUE BLUETM
LIMITED
WARRANTY
Effective January
1,
1992
(Equipment
with
a
serial
number
preface
of
ICC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties and is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
ii
LIMITED
WARRANTY
-
Subject
to
the
terms
and
conditions below.
MILLER Electric
Mtg.
Co..
Appleton.
WIsconsin,
warrants to
its
original
retail
purchaser
that new
MILLER
equipment
sold after the effective
date
of this
limited
warranty
is free of de
lads
in
material and
workmanship
at
the
time
it
is
shipped
by
MILLER. TIltS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING TNE WARRANTIES OF MERCHANTABILITY AND
FIT
NESS.
Within the
warranty
periods
listed
below.
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
tail
due
to
such
defects
in matenal
or
workmanship.
MILLER must
be
notified
in
writing
within
thIrty
130)
days
ot
such
defect
or
tsilure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall honor
warranty
claims
on
warranted
eguloment
lIsted
below
in
the
event
ot
such
a
lailure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that the
equipment
was
delivered
to
the
original
retail
purchaser.
or
one
year
after the
equipment
is
sent
to
the distributor
t.
5 Years
Parts 3 Years
Labor
*
Original
main
power
rectifiers
2. 3 Years

Parts
and Labor
*
Transtormer/Ractifler Power Sources

Plasma
Arc
Cutting
Power
Sources

Semi-Automatic
and Automatic Wire
Feeders
Robots
3.,
2
Years

Parts
and Labor

Engine
Driven
Welding
Generators
(NOTE
Engines
are
warranted
separately
by
the
engine
manufacturer.)

Air
Compressors
4.
t
Year

Parts
and Labor

Motor
Driven
Guns

Process
Controllers

Water
Coolant
Systems

HF
Units

Grids

Soot
Welders

Load Banks

SDX Transtormers

Running
Gear/Trailers

Field
Options
(NOTE.
Field
options
are
covered
under
True
Bluer
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year

whichever
is
greater
I
6 Months

Batteries
90
Days

Pans
and Labor

MIG Guns/TIG
Torches

Plasma
Cutting
Torches

Remote Controls

Accessory
Kits

Replacement
Pans
MILLERS True
Bluer
Limited
Warranty
shall
not
apply
to:
1.
Items
tumished
by
MILLER,
but
manutactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays
or
pans
that tail
due
to
normal
wear
3.
Equipment
that has been modified
by
any
party
other
than
MILLER.
or
equip
ment
that has been
improperly
installed,
improperly
operaled
or
misused
based
upon
industry
standards.
or
equipment
which has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which has
been used
tor
operation
outside of the
specifications
for
the
equipment.
MILLER PRODUCTS ARE INTENDED FOR
PURCHASE AND
USE
BY
COMMER
CIAL/INDUSTRIAL USERS
AND
PERSONS
TRAINED AND
EXPERIEHCED
IN
THE
USE
AND
MAINTENANCE OF WELDING EQUIPMENT
In
the
event
ot
a
warranty
claim covered
by
this
warranty,
the exclusive
remedies
shall
be,
at MILLERS
option
(1)
repair;
or
(2)
replacement;
or.
where
authorized
in
writing by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replace
ment at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
usel
upon
return
of
the
goods at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin.
or
F.O. B.
at
a
MILLER
authorized
ser
vice
tacility
as determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
ot
any
kind
will
be
allowed.
TO THE EXTENT PERMItTED BY
LAW.
THE
REMEDIES
PROVIDED
HEREIN
ARE THE
SOLE
AND
EXCLUSIVE REMEDIES.
IN
NO EVENT
SHALL
MILLER BE
LIABLE FOR
DIRECT, INDIRECt
SPECIAL, INCIDENTAL
OR CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS OF
PROFIT).
WHETHER
BASED
ON CON
TRACt TORT
OR.ANY
OTHER LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT PROVIDED HEREIN AND
ANY
IMPLIED
WAR
RANTY.
GUARANTY
OR
REPRESENTATION
AS TO
PERFORMANCE.
AND
ANY
REMEDY FOR BREACH OF CONTRACT TORT OR
ANY
OTHER LEGAL
THEORY
WHICH.
BUT FOR THIS
PROVISION,
MIGHT ARISE BY
IMPLICATION,
OPERATION
OF
LAW.
CUSTOM
OF TRADE OR
COURSE OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR PURPOSE,
WITH
RESPECT TO
ANY
AND ALL
EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED
BY MILLER.
Some
states
in
the
U.S.A.
do
not
allow limitations
ot
how
long
an
implied
warranty
lasts, or the exclusion ot incidental, indirect,
special
or
consequential
damages.
so
the
above limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spa
cilic
legal
rights,
and other
rights may
be
available,
but
may vary
from
slate
to state.
In
Canada,
legislation
in
some
provinces provides
(or certain
additional
warranties
or
remedies
other than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
esclusions
set out
above
may
not
apply.
This
Limited
Warranty
provides specific
legal rights,
and other
rights
may
be
available,
but
may
vary
from
province
to
province.
5.
6.
al-
RECEIVING-HANDLING
Before
Unpacking
equipment,
Check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
Claims
for
loss
or
damage
with the
delivering
carrier. Assistance
for
filing
or
settling
claims
may
be obtained
from
distributor and/or
equipment
manufacturers
Transportatton
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number of
your
unit,
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No,
Date of
Purchase
miller
5/93a

TABLE OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY RULES
FOR
OPERATION
OF ARC
WELDING
POWER SOURCE
1
-
1.
Introduction
1
1
-
2.
General
Precautions
1
1
-
3. Arc
Welding
4
1
-
4.
Standards
Booklet
Index
6
SECTION
2
-
INTRODUCTION
2
-
1.
General
Information
And
Safety
7
2
-
2.
Receiving-Handling
7
2
-
3.
Description
7
SECTION
3
-
INSTALLATION
3-1.
Location
8
3
-
2. Drive
Roll
And
Wire
Guide
Installation
8
3
-
3.
Welding
Gun
Connections
9
3
-4.
Drive
Motor
Connections
9
3
-
5.
Trailing
Gun Position
Adjustment
9
3
-
6.
Flux
Hopper
Connections
10
3
-
7.
Flux
Nozzle
Adjustment
10
3
-
8. Gun
Component Changes
When
Changing
Wire
Size 10
3
-
9.
Weld
Cable
Connections
11
SECTION
4
-
SEQUENCE
OF OPERATION
4
-
1.
Welding
Wire
Threading
11
4
-
2.
Submerged
Arc
Welding
(SAW)
12
4
-
3.
Shutting
Down
12
SECTION
5
-
MAINTENANCE
5
-
1.
Inspection
And
Upkeep
13
5
-
2.
Cleaning
Of
Drive
Rolls:
.
-
13
5
-
3.
Brush
Inspection
&
Replacement
13
SECTION
6
-
TROUBLESHOOTING
6-1.
General
14
6
-
2.
Troubleshooting
Chart
14

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
un
wise. 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,
opera
tion,
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
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to the
par
ticular
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
pro
cedures
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
ElectricalCode,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
Different
arc
welding
processes,
electrod.
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 alec
trode
manufacturers
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
cuftless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet with
safety
goggles
or
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
im
mediate
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
per
sons
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 Stan
dard.Z49.1
listed
1
in
Standards
index.
NEVER
ventilate
with
oxygen.
Lead
-,
cadmium
-,
zinc
-,
mercury
-,
and
beryllium
-
bearing
and
similar
materials,
when
welded
(or
cut)
may
produce
harmful
concentrations
of toxic
fumes.
Ade
quate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area as
well
as
the
operator
must
wear an
air-supplied
respirator.
For
beryllium,
both
must
be
us
ed.
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
ven
tilated,
or
the
operator
wears
an
air-supplied
respirator.
Work
in
a
confined
space
only
while it is
being
ven
tilated
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
con
centration
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
accidently
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
OM-1553
Page
1