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OM-316 087 083Q
August 2004
Processes
Stick (SMAW) Welding
Description
AC/DC, 300/200 AC/DC Models:
225 And 300 Models:
Arc Welding Power Source
Thunderbolt XL
AC/DC, 300/200 AC/DC, 225, And 300
Visit our website at
www.MillerWelds.com
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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 bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Insta
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage 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 Marks a special safety message. 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. 1-2. Arc Welding Ha
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. 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 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- (phone: 305-443-9353, website: www.aws.org). ternational.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection, ting of Conta
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SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux Identifie un message de sécurité particulier. PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symboles et
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LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation. tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien ventiler les espaces confinés ou porter un
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2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. Ne pas placer l’appareil sur une surface inflam- Se tenir à l’écart des organes mobiles comme les mable, ni au −dessus ou à proximité d’elle. ventilateurs. Maintenir fermés et bien fixés les portes, Ne pas installer l’appareil à proximité de produits inflammables. panneaux, recouvrements et dispositifs de
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2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463 −6727 ou à Toronto : (416) 747 −4044, site Web : www.csa−interna- (téléphone : (305) 443 −9353, site Web : www.aws.org). tional.org). Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protect
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SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Do Not Switch Amperes Single Phase Input Under Load A On Off Output Hertz Hz Alternating Electrode Positive Electrode Negative Direct Current Current Welding Arc Volts Work Electrode V 3-2. Manufacturer’s Rating Labels Rating Label For EN/FR Machines Rating Label For All Other Machines INPUT SERIAL NO. STOCK NO. V VOL TS A AMPERES KW KW Hz PHASE HERTZ LR5071 LR5071 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY EVIDENCE OFLABELTAMPERING VOIDS WARR
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SECTION 4 − INSTALLATION 4-1. Specifications AC/DC Models Maximum Amperes Input at Rated Load Output Rated Welding Amperage Open- 50 Or 60 Hz, Single-Phase Mode Mode W We eight ight Output Output Range Range Ci Circuit rcuit 115 V 220 V 230 V 400 V 460 V Voltage 225 A @ 25 Volts AC, Low: 30 − 150 AC 20% Duty Cycle @ 60 Hz; 80 VAC High: 40 − 235 15% Duty Cycle @ 50 Hz 104 lb 104 lb 95 95 47.5 47 5 23 23.7 7 (47 kg) 150 A @ 25 Volts DC, 4.6* 2.3* 1.2* DC 20% Duty Cycle @ 60 Hz; 30 − 160 80 VDC 1
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4-2. Duty Cycle Charts A. For AC/DC Models Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. 20% Duty Cycle at 225 Amperes. Ex- ceeding duty cycle can damage unit and void warranty. 2 Minutes Welding 8 Minutes Resting A. For 115/230, 230, And 460 Volt Models B. For 220, 230/400, And 460 Volt Models (225/150 Amperes*) (300/200 Amperes) *These models have a 15% duty cycle when used with 50 Hz input power. 086 727 / 099 602-A B. For AC Models Duty Cycle
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4-3. Volt-Ampere Curves A. For AC/DC Models The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. A. For 115/230, 230 And 460 Volt Models (225/150 Amperes) 90 80 80 70 70 60 60 50 50 40 40 30 30 20 20 10 10 0 0 0 50 100 150 200 250 300 350 0 50 100 150 200 250 AC Amperes DC Amperes B. For 220, 230/400, And 460 Volt Models (300/200 Amperes) 100 100 A=LOW RANGE 90 90 B=HIGH RANGE 80 80 70 70 60 60 50
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B. For AC Models The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. A. For 115/230 And 230 Volt Models (225 Amperes) 90 A=LOW RANGE 80 B=HIGH RANGE 70 60 50 40 30 20 A BB A 10 0 0 50 100 150 200 250 300 AC Amperes B. For 220 Volt Model C. For 230/400 Volt Model (300 Amperes) (300 Amperes) 100 A=LOW RANGE 90 90 B=HIGH RANGE 80 80 70 70 60 60 50 50 40 40 30 30 20 20 10 A 10 A B B 0 0 0 100 200 300
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4-4. Selecting A Location 1 Rating Label (See Section 3-2) Locate unit near correct input 1 power. Special installation may be required where gasoline or volatile liquids are present − V see NEC Article 511 or CEC 18 in (457 mm) for airflow A Section 20. KW Hz LR5071 EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY TOUTE ALTÉRATION DE L ’ÉTIQUETTE ANNULLE LA GARANTIE 217 652-A / 802 105 OM-316 Page 14
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4-5. Installing Electrode Holder And Work Clamp Turn Off unit and disconnect input power before installing electrode holder or work clamp. Removing Barrel From Elec- trode Holder 1 Electrode Holder 2 Barrel 3 Access Hole 4 Set Screw 3 Loosen set screw through access 2 hole and slide barrel away from electrode holder. Installing Electrode Cable and 4 5 Barrel onto Electrode Holder 1 5 Electrode Cable From Unit (Has Bare Conductors on End) 6 Terminal Screw Back out terminal screw from elec- trod
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4-7. Electrical Service Guide Input Voltage 115 220 230 400 460 47.5 23.7 95 [70] [39] Input Amperes At Rated Output [67] [34] Max Recommended Standard Fuse Or Circuit Breaker Rating 70 35 150 [110] [60] [100] [50] In Amperes 12 14 8 [8] [14] Min Input Conductor Size In AWG/Kcmil [10] [14] 87 (26) [101 138 (42) Max Recommended Input Conductor Length In Feet (Meters) 32 (10) [75 (23)] [82 (25)] (31)] [87 (27)] 14 Min Grounding Conductor Size In AWG/Kcmil 8 [8] 12 [10] [14] [14] [ ] Electrical Ser
