Miller Electric 225, 300 manual Welding Methods & Troubleshooting

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SECTION 8 − WELDING METHODS & TROUBLESHOOTING

mod5.1* 9/92

A. Welding Methods

8-1. Shielded Metal Arc Welding (SMAW) Procedure

1 7

Tools Needed:

151 593

1 Workpiece

Make sure workpiece is clean before welding.

2 Work Clamp

Place as close to the weld as possible.

3 Electrode

A small diameter electrode requires less current than a large one. Follow recommendations of electrode manufacturer when setting weld amperage (see 8-2).

4 Insulated Electrode Holder

5Electrode Holder Position

6Arc Length

Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound.

YWelding current starts as soon as electrode touches the workpiece.

7 Slag

Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass.

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Contents Visit our website at OM-316087 083Q August ProcessesDescription Stick Smaw WeldingFrom Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can killFlying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explosion Buildup of GAS can injure or killCalifornia Proposition 65 Warnings EMF Information Principal Safety StandardsAbout Pacemakers LES Décharges Électriques peuvent être mortelles Signification des symboles− Consignes DE Sécurité − À Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxLES Pièces Chaudes peuvent cau- ser des brûlures graves LE Soudage peut causer un incen- die ou une explosionLES Particules Projetées peu- vent blesser les yeux LE Bruit peut affecter l’ouïe’EMPLOI Excessif peut Faire Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser LES Pièces Mobiles peuvent cau- ser des blessuresRexdale, Rexdale Ontario Canada M9W 1R3 téléphone Principales normes de sécuritéInformation sur les champs électromagnétiques Consignes relatives aux stimulateurs cardiaques− Definitions Symbols And DefinitionsManufacturer’s Rating Labels AC/DC Models − InstallationSpecifications AC ModelsFor AC/DC Models Duty Cycle ChartsVoid warranty For AC ModelsFor 115/230, 230 And 460 Volt Models 225/150 Amperes Volt-Ampere CurvesFor 220, 230/400, And 460 Volt Models 300/200 Amperes For 220 Volt Model For 230/400 Volt Model Amperes For 115/230 And 230 Volt Models 225 AmperesAC Amperes Selecting a Location 18 in 457 mm for airflowInstalling Work Cable onto Work Clamp Installing Electrode Holder And Work ClampInstalling Electrode Cable and Barrel onto Electrode Holder Weld Output Cables47.5 Electrical Service Guide115 220 230 400 460 150Tools Needed 16, 3/8 Cut tie wraps Turn Off unit and disconnect input power10 115 V Input Power Cord White Lead Wrapper Remove wrapper Jumper LeadsConnected For 400 Volts Connected For 230 Volts Connecting Input Power Controls For AC/DC Models − OperationControls For DC Weld OutputControls For AC Models Lubricating Shunt Block And Anti-Noise Adjustment − Maintenance & TroubleshootingRoutine Maintenance MonthsWrapper Remove wrapper from unit Crank Handle Shunt Shaft Reinstalling Amperage Adjustment IndicatorTorx Troubleshooting Trouble Remedy− Electrical Diagrams Circuit Diagram For AC/DC 230 Volts ModelsCircuit Diagram For AC/DC 115/230 Volts Models Circuit Diagram For 300/200 AC/DC 230/400 Volts Models Circuit Diagram For 225 230 Volts Models Circuit Diagram For 300 220 Volts Models − Welding Methods & Troubleshooting Welding Methods Shielded Metal Arc Welding Smaw ProcedureElectrode And Amperage Selection Chart Positioning The Electrode Holder Striking An Arc10−30 Electrode Angle Weld Bead CharacteristicsConditions That Affect Weld Bead Shape Arc LengthDo not let weave width Electrode Movement During WeldingButt Joints Tack WeldsTee Joints Welding TroubleshootingLap Joints PorosityIncomplete Fusion Excessive SpatterLack Of Penetration Waviness Of Bead Excessive PenetrationBurn-Through Distortion− Parts List Main Assembly AC/DC model illustratedMain Assembly Page Work like a Pro TM-188 304 Invision 354MP Your distributor also gives ServiceSupport Your distributor and/or equipment manufacturer’s Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Transportation Department