Miller Electric HF-251D-1 Owner's Manual
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Miller Electric HF-251D-1 Owner's Manual

High frequency arc starter
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OM-611
096 556U
January 2004
Processes
TIG (GTAW) Welding
Description
High Frequency Arc Starter
HF-251D-1 And HF-251-2
Visit our website at
www.MillerWelds.com

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Summary of Contents for Miller Electric HF-251D-1

  • Page 1 OM-611 096 556U January 2004 Processes TIG (GTAW) Welding Description High Frequency Arc Starter HF-251D-1 And HF-251-2 Visit our website at www.MillerWelds.com...
  • Page 2 ISO 9001:2000 Quality System Standard. 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.
  • Page 6 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. D 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).

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards 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 Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W.

  • Page 9: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT 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. Y Identifie un message de sécurité particulier. Signifie «...
  • Page 10 LES RAYONS DE L’ARC peuvent cau- ser des brûlures oculaires et cuta- nées. Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) suscep- tibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. D Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour re- garder (voir les normes de sécurité...

  • Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- SION D Ne pas placer l’appareil sur une surface inflam- mable, ni au−dessus ou à proximité d’elle. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique −...

  • Page 12: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, norme American Welding Society AWS F4.1, de l’American Welding Society, 550 N.W.

  • Page 13: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Specifications Welding Input Power Type Of Input Power Circuit Rat- Circuit Rat- Cord With Cord With 115 Volts Plug 115 Volts AC 250 Amperes Single-Phase At 60% Duty 10 ft (3 m) 50/60/100 Hz, Cycle 1.5 Amperes 3-2.

  • Page 14: Installing Gas Supply

    3-3. Installing Gas Supply Argon Gas IN-GAS-OUT Tools Needed: 1-1/8, 5/8 in OM-611 Page 10 To Torch Return To Table Of Contents Obtain gas cylinder and chain to running gear, wall, or other station- ary support so cylinder cannot fall and break off valve.

  • Page 15: Power Source Plug Information And Connections

    NOTE The supplied cord with plugs is for use with CC or CC/CV welding power sources having the proper, matching 14-pin receptacle. Do not use cordset on machines without the 14-pin receptacle. 3-4. Power Source Plug Information And Connections Connect Remote 14 Plug PLG4 if remote contactor and/or remote amperage control from the HF unit are desired.

  • Page 16: Operator Control Receptacle Information And Connections

    3-5. Operator Control Receptacle Information And Connections C L N 3-6. Operator Control Receptacle Socket Information Socket* A, B *The remaining sockets are not used. OM-611 Page 12 The 14-socket Operator Control receptacle RC1 on the front of the high- frequency unit is used to connect an optional Amperage Control and/or a remote start switch to the control circuitry of the high-frequency unit.

  • Page 17: Connecting To Weld Output Terminals

    3-7. Connecting To Weld Output Terminals CAUTION Welding Power Source Or Generator WORK ELECTRODE Tools Needed: 3/4 in ELECTRODE IN ELECTRODE OUT WORK INPUT/OUTPUT CONNECTING CABLES TO HF unit will damage welding power source or welding generator. HF Unit ALWAYS connect WORK cables to this terminal for HF protection.

  • Page 18: Connecting Input Power

    3-8. Connecting Input Power OM-611 Page 14 Return To Table Of Contents Y Read and follow entire Sec- tion 8 about HF equipment be- fore installing unit. Y Direct Current (DC) will dam- age HF Unit. Connect unit only to Alternating Current (AC) supply.

  • Page 19: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls 4-2. High Frequency Switch 4-3. High Frequency Selector Switch Return To Table Of Contents Power Switch Pilot Light High Frequency Selector Switch High Frequency Switch High Frequency Intensity Control Ref. 098 956-D High Frequency Switch Start −...

  • Page 20: High Frequency Intensity Control

    4-4. High Frequency Intensity Control 4-5. Power Switch And Pilot Light 4-6. Postflow Timer 4-7. Shielding Gas OM-611 Page 16 Return To Table Of Contents High Frequency Intensity Control Use control to change amount of HF energy used to start and/or maintain the arc.

  • Page 21: Section 5 − Maintenance & Troubleshooting

    SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance 3 Months Tape Or Replace Cracked Cables Replace Unreadable Labels Clean Tighten Weld Terminals Disconnect all power before maintaining. 155 457 Return To Table Of Contents 3 Months Replace Cracked Parts 14-Pin Cord Gas Hose Torch Cable...

  • Page 22: Adjusting Spark Gaps

    5-2. Adjusting Spark Gaps Tools Needed: 5/32 in OM-611 Page 18 Rear Of Unit 0.008 in (0.203 mm) Return To Table Of Contents Turn Off unit and welding power source and disconnect input power. Loosen screw on spark gap access door and open.

  • Page 23: Troubleshooting

    5-3. Troubleshooting Trouble Unit completely inoperative; Pilot light Secure input power cord plug in receptacle (see Section 3-8). Off. Place Power switch in the On position (see Section 4-5). Lack of high-frequency; difficulty in es- Place High Frequency Selector Switch in the correct position (see Section 4-3). tablishing an arc.

  • Page 24: Section 6 − Electrical Diagrams

    SECTION 6 − ELECTRICAL DIAGRAMS 130 555-D Figure 6-1. Circuit Diagram For 115 Volts Model OM-611 Page 20 Return To Table Of Contents...
  • Page 25 140 903-E Figure 6-2. Circuit Diagram For 230 Volts Model OM-611 Page 21 Return To Table Of Contents...

  • Page 26: Section 7 − High Frequency

    SECTION 7 − HIGH FREQUENCY 7-1. Welding Processes Requiring High Frequency 7-2. Incorrect Installation Sources of Direct High-Frequency Radiation High-Frequency Source (welding power source with built-in HF or separate HF unit) Weld Cables Torch Work Clamp Workpiece Work Table OM-611 Page 22 Work Weld Zone 11, 12...

  • Page 27: Correct Installation

    7-3. Correct Installation 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Nonmetal Building High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.

  • Page 28: Section 8 − Selecting And Preparing Tungsten Electrode For Dc Or Ac Welding

    SECTION 8 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING Y Whenever possible and practical, use DC weld output instead of AC weld output. 8-1. Selecting Tungsten Electrode ( Electrode Diameter DC − Argon − Electrode 2% Ceria (Orange Band), 1.5% Lan- thanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens .010”...

  • Page 29: Preparing Tungsten Electrode For Welding

    8-2. Preparing Tungsten Electrode For Welding Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor- mation.

  • Page 30: Torch Movement During Welding

    9-2. Torch Movement During Welding Tungsten Without Filler Rod Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool.
  • Page 31 Notes Return To Table Of Contents OM-611 Page 27...

  • Page 32: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 098 955-L Part 1 of 2 Figure 10-1. Complete Assembly (Part 1 of 2) (115V Model) OM-611 Page 28 Return To Table Of Contents...
  • Page 33 Item Dia. Part Mkgs....206 108 ....+129 366 ..
  • Page 34 Hardware is common and not available unless listed. 098 955-L Part 2 of 2 Figure 10-2. Complete Assembly (Part 2 of 2) (115V Model) OM-611 Page 30 Return To Table Of Contents...
  • Page 35 Item Dia. Part Mkgs... . 035 704 ....031 630 ....107 983 .
  • Page 39 Warranty Questions? Call LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 40: Owner's Record

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2004 Miller Electric Mfg. Co. 1/04 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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Hf-251-2

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