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

Miller HF-251D-1 Owner's Manual

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OM-611
096 556M
April 2001
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 HF-251D-1

  • Page 1 OM-611 096 556M April 2001 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 – every power source from This Owner’s Manual is designed to help you get the most out of your Miller is backed by the most Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the business.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

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

    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. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

  • Page 9: Section 1 - Consignes De Securite - Lire Avant Utilisation

    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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 13: Specifications

    SECTION 2 – INSTALLATION 2-1. Specifications Welding Input Power Type Of Input Power Dimensions Weight Circuit Rat- Cord With 115 Volts 230 Volts Height Width Length 115 Volts 230 Volts Plug 115 Volts AC 230 Volts AC Net: Net: 250 Amperes 15 in 9-1/4 in 16 in...

  • Page 14: Installing Gas Supply

    2-3. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- ary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from 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. 2-4. Power Source Plug Information And Connections Y Turn Off HF Unit and welding power source, and discon- nect input power before making connections.

  • Page 16: Operator Control Receptacle Information And Connections

    2-5. Operator Control Receptacle Information And Connections Operator Control Receptacle RC1 (See Section 2-6) Keyway Plug Threaded Collar To connect to receptacle, align keyway, insert plug, and tighten threaded collar. C L N 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

    2-7. Connecting To Weld Output Terminals Y Turn Off HF Unit and welding power source, and discon- nect input power before making connections. Stop engine on welding genera- tors. Y Not connecting work cables to HF Unit will damage power source.

  • Page 18: Connecting Input Power

    2-8. Connecting Input Power 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. Do not cut grounding terminal off plug. Grounded Receptacle See Section 2-1 for type of input power required.

  • Page 19: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Controls Power Switch Pilot Light High Frequency Selector Switch High Frequency Switch High Frequency Intensity Control Ref. ST-098 956-D 3-2. High Frequency Switch High Frequency Switch Start – provides HF for arc starting only. Off – provides no HF. Use Off for SMAW welding.

  • Page 20: High Frequency Intensity Control

    3-4. High Frequency Intensity Control High Frequency Intensity Control Use control to change amount of HF energy used to start and/or maintain the arc. Set as low as practical to prevent interfering with electronic equipment. 3-5. Power Switch And Pilot Light Power Switch Use switch to turn unit On and Off.

  • Page 21: Section 4 - Maintenance & Troubleshooting

    SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Disconnect all power before maintaining. 3 Months 3 Months Tape Or Replace Replace Cracked Cracked Parts Cables 14-Pin Cord Replace Unreadable Labels Gas Hose Torch Cable Clean Adjust Spark Tighten Gaps Weld Terminals 6 Months...

  • Page 22: Adjusting Spark Gaps

    4-2. Adjusting Spark Gaps Turn Off unit and welding power source and disconnect input power. Rear Of Unit Loosen screw on spark gap access door and open. Tungsten End Of Point Do not clean or dress tungsten. Replace point if tungsten end disappears.

  • Page 23: Troubleshooting

    4-3. Troubleshooting Trouble Remedy Unit completely inoperative; Pilot light Secure input power cord plug in receptacle (see Section 2-8). Off. Place Power switch in the On position (see Section 3-5). Lack of high-frequency; difficulty in es- Place High Frequency Selector Switch in the correct position (see Section 3-3). tablishing an arc.

  • Page 24: Section 5 - Electrical Diagrams

    SECTION 5 – ELECTRICAL DIAGRAMS SB-130 555-A Figure 5-1. Circuit Diagram For 115 Volts Model OM-611 Page 20...
  • Page 25 SB-140 903-A Figure 5-2. Circuit Diagram For 230 Volts Model OM-611 Page 21...

  • Page 26: Section 6 - High Frequency

    SECTION 6 – HIGH FREQUENCY 6-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG – helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work high_freq 12/96 – S-0693 6-2. Incorrect Installation Weld Zone 11, 12 50 ft (15 m) Sources of Direct High-Frequency...

  • Page 27: Correct Installation

    6-3. Correct Installation Weld Zone 50 ft (15 m) 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by codes. Nonmetal Building Metal Building Ref. S-0695 / Ref. S-0695 High-Frequency Source (welding Conduit Joint Bonding and Grounding Metal Building Requirements...

  • Page 28: Section 7 - Selecting And Preparing Tungsten Electrode

    SECTION 7 – SELECTING AND PREPARING TUNGSTEN ELECTRODE gtaw 7/97 NOTE For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent contamination of tungsten electrode. 7-1. Selecting Tungsten Electrode ♦...

  • Page 29: Preparing Tungsten For Ac Or Dc Electrode Positive (Dcep) Welding

    7-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding Tungsten Electrode Balled End Y Understand follow safety symbols at start of Section 8-1 before preparing tungsten. Ball end of tungsten before welding 1-1/2 Times by applying either an ac amperage Electrode Diameter slightly higher than what is recom- mended for a given electrode diam-...

  • Page 30: Section 8 - Guidelines For Tig Welding (Gtaw)

    SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW) 8-1. Positioining The Torch Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Workpiece Make sure workpiece is clean before welding.

  • Page 31: Positioning Torch Tungsten For Various Weld Joints

    8-3. Positioning Torch Tungsten For Various Weld Joints ° Butt Weld And Stringer Bead ° ° ° “T” Joint ° ° ° ° Lap Joint ° ° ° ° Corner Joint ° ° ST-162 003 / S-0792 OM-611 Page 27...

  • Page 32: Section 9 - Parts List

    SECTION 9 – PARTS LIST Hardware is common and not available unless listed. ST-098 955-K Part 1 of 2 Figure 9-1. Complete Assembly (Part 1 of 2) (115V Model) OM-611 Page 28...
  • Page 33 Quantity Model Item Dia. Part Mkgs. Description 115V 230V Figure 9-1. Complete Assembly (Part 1 of 2) ....126 415 CLAMP, saddle ......... . .
  • Page 34 Hardware is common and not available unless listed. ST-098 955-L Part 2 of 2 Figure 9-2. Complete Assembly (Part 2 of 2) (115V Model) OM-611 Page 30...
  • Page 35 Quantity Model Item Dia. Part Mkgs. Description 115V 230V Figure 9-2. Complete Assembly (Part 2 of 2) ... 035 704 RECTIFIER, integ 40A 800V ....... .
  • Page 36 Notes...
  • Page 37 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...

  • Page 38: Options And Accessories

    Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

This manual is also suitable for:

Hf-251-2

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