Miller Maxstar 200 LX Owner`s manual

OM-2226
189783G
April 2002
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
115/230/400/460 Volt Models W/AutolineR
Arc Welding Power Source
R
Maxstar 200 SD,
DX, And LX
And Non-CE Models
Visit our website at
www.MillerWelds.com
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 build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
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 orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
5
5
5
SECTION 2 – DEFINITIONS (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturer’s Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
11
12
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Automation 10-Pin Connection (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. TIG HF Impulse/ Lift-Arct DCEN (Direct Current Electrode Negative) Connections . . . . . .
3-10. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) . . . . .
3-11. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . .
3-13. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
14
15
16
17
17
18
19
19
20
21
22
23
24
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Ammeter And Volt Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Lift-Arct And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Stick Start Procedure – Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Adjust Controls (Post Flow/DIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Pulser Control (DX And LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Sequencer Controls (DX, LX And All CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Preflow Adjust (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Programmable TIG HF Impulse Start Amperage And Time Modes . . . . . . . . . . . . . . . . . . . . .
4-14. Reconfiguring 2T For 4T, 4T Momentary, Mini Logic Control, Or Spot
. . . . (DX, LX And All CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. 4T Specific Trigger Method (DX, LX And All CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Mini Logic Operation (DX, LX And All CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Spot Control Operation (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. 4T Momentary Operation (DX, LX And All CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19 Arc Timer/Counter Display (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22. Setting Unit To Display PPP While Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
25
27
27
27
28
29
30
32
33
34
35
36
38
7
8
8
44
48
49
50
51
52
54
57
58
(Continued)
TABLE OF CONTENTS
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
58
58
59
60
SECTION 6 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
SECTION 7 – HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
62
62
63
SECTION 8 – SELECTING AND PREPARING TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . .
8-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
64
65
SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
66
67
68
SECTION 10 – STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Stick Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Electrode and Amperage Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Striking an Arc – Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Striking an Arc – Tapping Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Positioning Electrode Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-9. Electrode Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-10. Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-11. Lap Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-12. Tee Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-13. Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-14. Troubleshooting – Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-15. Troubleshooting – Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-16. Troubleshooting – Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-17. Troubleshooting – Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-18. Troubleshooting – Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-19. Troubleshooting – Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-20. Troubleshooting – Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-21. Troubleshooting – Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
69
70
70
70
71
71
71
72
72
73
73
73
74
74
74
75
75
75
76
76
76
SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
OPTIONS AND ACCESSORIES
WARRANTY
Declaration of Conformity For
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit.)
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
Maxstar R 200 SD, DX, LX
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Capability Directives: 89/336, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(December 1996 – Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
European Contact:
Telephone:
Fax:
dec_con1 10/95
Mr. Danilo Fedolfi, Managing Director
MILLER Europe S.r.l.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
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.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-2226 Page 1
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).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-2226 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
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
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.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-2226 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-2226 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
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.
Y Identifie un message de sécurité particulier.
. Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Y Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de
sécurité.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique, et décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.
D Ne jamais toucher les pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.
D
D
D
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
D Installer et mettre à la terre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D
D
D
D
D
D
D Eloigner votre tête des fumées. Ne pas respirer
les fumées.
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un
surveillant dûment formé de se tenir à proximité. Des fumées et des
gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
rayons de l’arc peuvent réagir en présence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien
ventilé, et si nécessaire, en portant un respirateur à alimentation
d’air. Les revêtements et tous les métaux renfermant ces éléments
peuvent dégager des fumées toxiques en cas de soudage.
OM-2226 Page 5
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées
pendant le soudage.
D Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
D Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être
projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D Se protéger et d’autres personnes de la projection d’étincelles et de
métal chaud.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur
des substances inflammables.
D Déplacer toutes les substances inflammables à une distance de 10,7
m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.
D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par
des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-2226 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
D
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.
D Ne pas toucher des parties chaudes à mains nues
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de
se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec une
bouteille.
D Ne jamais souder une bouteille pressurisée – risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables.
D Rester à l’écart des organes mobiles comme le
ventilateur.
D Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables
D Ne pas surcharger l’installation électrique – s”assurer que l’alimentation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un engin d’une capacité appropriée pour
soulever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
D
D
D Prévoir une période de refroidissement, respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
D Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil
de soudage.
D Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de radio–navigation et de communication, les services
de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.
D
D
D
D
D
D L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-2226 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-2226 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – DEFINITIONS (CE Models)
2-1. Warning Label Definitions
Warning! Watch Out! There are possible
hazards as shown by the symbols.
1
Electric shock from welding electrode
or wiring can kill.
2
2.1
2.2
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
2.3
3
1.2 Protect yourself from electric shock by
insulating yourself from work and
ground.
3.1
3.2
1.3 Disconnect input plug or power before
working on machine.
1
1.1
2
2.1
3
3.1
1.2
Breathing welding fumes can be
hazardous to your health.
Keep your head out of the fumes.
Use forced ventilation or local exhaust
to remove the fumes.
Use ventilating fan to remove fumes.
Welding sparks can cause explosion
or fire.
Keep flammables away from welding.
Do not weld near flammables.
Welding sparks can cause fires. Have
a fire extinguisher nearby, and have a
watchperson ready to use it.
1.3
2.2
2.3
3.2
4
3.3 Do not weld on drums or any closed
containers.
4
Arc rays can burn eyes and injure
skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
5
Become trained and read the
instructions before working on the
machine or welding.
6
Do not remove or paint over (cover)
the label.
4.1
5
3.3
6
S-179 310-A
OM-2226 Page 9
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
2
1
2
4
3
5
V
V
> 60 s
V
3
4
5
6
S-185 836
7
6
9
8
7
8
9
1
1
2
3
∠ = <60 °
4
∠
5
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
Always wait 60 seconds after
power is turned off before
working on unit, OR
Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
Always wear long sleeves and
button your collar when
servicing unit.
After taking proper
precautions as shown,
connect power to unit.
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
Use a proper cart to move
unit.
Do not use one handle to lift
or support unit.
S-179 309-A
2
3
4
5
1/96
OM-2226 Page 10
2-2. Manufacturer’s Rating Label
. See
Section 3-4 for
location.
. Use rating label to determine input power
requirements.
f1
EN 60974–1
f2
1A 10V
S
U
o
80V
200A 18V
U
o
80V
1
=115V
40%
60%
100%
70%
100%
I2
200
175
150
150
125
18
17
16
16
15
X
40%
60%
100%
50%
80%
I2
175
150
125
125
100
27
26
25
25
24
U
2
1A 20V
S
U
X
200A 28V
U
2
I 1 max
U
1
=115V
I 1 eff
1
50/60 Hz
U
1
=115V
35
25
1
50/60 Hz
U
1
=230V
31
17
3
50/60 Hz
U
1
=230V
19
11
3
50/60 Hz
U
1
=400V
11
6
3
50/60 Hz
U
1
=460V
9
5
IP23
195 646-B
OM-2226 Page 11
2-3. Symbols And Definitions
A
Amperes
Panel–Local
V
Volts
Voltage Input
Voltage Output
Circuit Breaker
Remote
Protective Earth
(Ground)
Postflow Timer
Preflow Timer
On
Off
Positive
Alternating
Current
Gas Input
Gas Output
Duty Cycle
Direct Current
Line Connection
X
U1
U0
Primary Voltage
IP
Degree Of
Protection
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
3 Phase Static Frequency
Converter-Transformer-Rectifier
I1max
Rated Maximum
Supply Current
Lift-Arc Start
(GTAW)
S
Seconds
Negative
I2
Rated Welding
Current
U2
Conventional Load
Voltage
I1eff
Maximum Effective
Supply Current
Rated No Load
Voltage (Average)
Pulse Background
Amperage
Initial Amperage
Increase/Decrease
Of Quantity
Normal Trigger Operation (GTAW)
Two-Step Trigger
Operation (GTAW)
Four-Step Trigger
Operation (GTAW)
Percent
Hertz
Recall From
Memory
Arc Force (DIG)
HF Impulse Starting (GTAW)
Final Slope
Final Amperage
Pulse Percent
On Time
Initial Slope
Contactor Control
(Stick)
Pulser On-Off
TIG Weld Amps
And Peak Amps
While Pulsing
Pulse Frequency
Background Amps
Process
Pulser
Sequence
Output
Adjust
Suitable For Areas
Of Increased
Shock Hazard
Hz
OM-2226 Page 12
S
SECTION 3 – INSTALLATION
3-1. Specifications
Amperes Input At Rated Output, 50/60Hz
Welding
Amperage
Range
Max.
Open-Circuit
Voltage
150 A @ 26 VDC,
60% Duty Cycle
1 – 200
9-14♦
TIG Process
175 A @ 17 VDC,
60% Duty Cycle
1 – 200
9-14♦
Three-Phase
Stick Process
200 A @ 28 VDC,
30% Duty Cycle
1 – 200
80
18.4
10.3
8.9
7.3
7.0
9-14♦
0.16*
0.24*
0.25*
0.06*
0.03*
Three-Phase
TIG Process
200 A @ 18 VDC,
40% Duty Cycle
1 – 200
80
12.7
7.2
6.2
5.1
4.9
9-14♦
0.16*
0.24*
0.25*
0.06*
0.03*
Single-Phase
150 A @ 26 VDC,
60% Duty Cycle
1 – 200
-–
21.7
0.23*
-–
10.6
9-14♦
5.0
0.05*
5.0
0.02*
175 A @ 17 VDC,
60% Duty Cycle
1 – 200
9-14♦
-–
0.23*
125 A @ 25 VDC,
50% Duty Cycle
1 – 200
80
34.1
0.42*
-–
150 A @ 16 VDC,
70% Duty Cycle
1 – 200
9-14♦
29.7
0.42*
100 A @ 24 VDC,
80% Duty Cycle
1 – 200
9-14♦
125 A @ 15 VDC,
100% Duty Cycle
1 – 200
9-14♦
Input Power
Three-Phase
Stick Process
Three-Phase
Stick Process
Single-Phase
TIG Process
Single-Phase
Stick Process
Single-Phase
TIG Process
Single-Phase
Stick Process
Single-Phase
TIG Process
Rated Output
80
80
80
80
5.2
0.06*
5.0
0.03*
400
460
-–
13.1
0.16*
7.4
0.24*
6.4
0.25*
10.5
6.0
5.2
4.2
4.0
-–
0.16*
0.24*
0.25*
0.06*
0.03*
80
9-14♦
KW
230
80
80
KVA
115
17.4
.25*
8.5
4.0
4.0
.25*
0.05*
0.02*
-–
-–
4.0
0.05*
3.8
0.03*
-–
-–
-–
28.1
0.42*
-–
-–
-–
23.0
0.42*
-–
-–
-–
-–
3.4
3.4
0.05*
0.03*
3.2
3.2
0.05*
0.03*
2.6
2.6
0.05*
0.03*
*While idling
♦Sense Voltage For Stick And TIG Lift Arct
NOTE: Duty cycle limitations on units with 115 volt input power are due to the input power cord supplied with the unit.
OM-2226 Page 13
3-2. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of welding
power source. Curves of other settings fall between curves shown.
Volts
115VAC Input
140
120
100
80
60
40
20
0
Stick Max.
TIG Max.
Stick/TIG Min.
DIG Max.
0
50
100
150
200
250
Amperes
Volts
Other Input Voltages
140
120
100
80
60
40
20
0
Stick Max.
TIG Max.
Stick/TIG Min.
0
50
DIG Max.
100
150
200
250
Amperes
ST- 189 767
OM-2226 Page 14
3-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 5-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
90 A @ 100% Duty Cycle For 115 Volt Single-Phase Stick Process
125 A @ 100% Duty Cycle For 115 Volt Single-Phase TIG Process
150 A @ 60% Duty Cycle For Stick Process (Other Voltages)
175 A @ 60% Duty Cycle For TIG Process (Other Voltages)
6 Minutes Welding
4 Minutes Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
ST-189 770-A
OM-2226 Page 15
3-4. Selecting A Location
1
2
3
Dimensions And Weight
34.7 lb (15.7 kg) - without power cord
37.3 lb (16.9 kg) - with power cord
Identification Plate
Rating Label
Line Disconnect Device
Locate unit near correct input
power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
17-1/4 in
(438 mm)
13-3/8 in
(333 mm)
7-9/16 in
(192 mm)
1
SERIAL NO.
Location And Airflow
3
STOCK NO.
EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY
f1
f2
EN 60974–1
1A 10V
S
18 in
(460 mm)
40%
X
I2
U2
40%
200
18
1A 20V
S
18 in
(460 mm)
Uo 80V
X
I2
U2
1
1
3
3
3
Uo 80V
50/60
50/60
50/60
50/60
50/60
Hz
Hz
Hz
Hz
Hz
175
27
U 1 =115V
U 1 =230V
U 1 =230V
U 1 =400V
U 1 =460V
200A 18V
60% 100%
150
175
17
16
U 1 =115V
70% 100%
125
150
16
2
15
200A 28V
60% 100%
125
150
26
25
U 1 =115V
50% 80%
100
125
I1 max
I1 eff
35
31
19
11
9
25
17
11
6
5
25
24
IP23
ST-802 451
OM-2226 Page 16
3-5. Weld Output Terminals And Selecting Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding
Y Turn off power before
connecting to weld output terminals.
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
+
100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
400 ft
(105 m) (120 m)
Welding
Amperes***
10 – 60%
Duty
Cycle
60 – 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
10 – 100% Duty Cycle
–
Output Receptacles
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***Select weld cable size for pulsing application at peak amperage value.
S-0007-E–
3-6. Remote 14 Receptacle Information
Socket*
A
B
K
Socket Information
J
I
A
Contactor control +15 volts dc.
B
Contact closure to A completes 15 volts dc
contactor control circuit and enables output.
C
Output to remote control; 0 to +10 volts dc output
to remote control.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
A/V
F
Current feedback; +1 volt dc per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt dc per 10 volts output.
GND
G
+15 volts dc GND
CHASSIS
K
Chassis common.
15 VOLTS DC
H
C L N
D M
G
E F
OUTPUT
CONTACTOR
REMOTE
OUTPUT
CONTROL
ST-802 541
*The remaining sockets are not used.
Note: If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the
remote control before the Panel or Remote contactor is turned on. Failure to do so, will cause current to be controlled by the panel control and
the remote hand control will not function.
OM-2226 Page 17
3-7. Automation 10-Pin Connection (LX Models)
Socket
F
A
Start/Stop
B
Gas
C
Output enable
D
Chassis ground
E
Final slope – collector
F
Final slope – emitter
G
Pulse lockout – collector
H
Pulse lockout – emitter
I
Valid arc – collector
J
Valid arc – emitter
E
G
D
J
H
Socket Information For 10-Pin Receptacle RC2
C
I
A
B
Ref. ST-802 458
Definitions Of Inputs And Outputs
Inputs
A - Closure to D starts the weld cycle. Opening closure stops weld cycle. During 2T operation, a momentary closure (greater than 100ms, but
less than 3/4 seconds) starts and stops weld output.
B - Closure to D turns on gas. If a preflow time is entered, the preflow cycle will time out before arc initiation. If a post flow time is entered, the
post flow cycle will time out at the end of the weld, even if B to D closure is opened.
C - Closure to D must be maintained at all times. If the closure between pins C and D is broken, an output disable occurs, Postflow begins to
time out, and HELP 13 will be displayed on the meters.
Outputs
Outputs are isolated open-collector transistor which are able to conduct at least 6 mA of current, with a maximum of 100 mA of current and 30
VDC.
Final Slope - output is on when in Final Slope.
Pulse Lockout - output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, during background time, and when the pulse
frequency is less than 10 Hz.
Arc On - output is on when the contactor is on and amperage is greater than 5 amps, or output voltage is greater than 5 volts but less than 50
volts.
OM-2226 Page 18
3-8. Gas Connections
1
Gas Fitting
Fittings have 5/8-18 right-hand
threads (3/8-19 BSPP on CE units).
2
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
3
4
2
3
4
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
1
Connect customer supplied gas
hose between regulator/flowmeter
and gas fitting on rear of unit.
Tools Needed:
11/16, 1-1/8 in, (21 mm)
ST-802 452
3-9. TIG HF Impulse/ Lift-Arct DCEN (Direct Current Electrode Negative) Connections
Y Turn off power before making connections.
1
Negative (–) Weld Output
Terminal
Connect TIG torch to negative weld
output terminal.
2
Gas Out Connection
Connect torch gas hose to gas out
fitting.
3
Positive (+) Weld Output
Terminal
Connect work lead to positive weld
output terminal.
4
Remote 14 Receptacle
Connect desired remote control to
Remote 14 receptacle.
5
5
Gas In Connection
Connect gas hose from gas supply
to gas in fitting.
3
2
4
1
Tools Needed:
11/16 in, (21 mm)
Ref. ST-802 471
OM-2226 Page 19
3-10. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)
1
Front Panel
Correct front panel display for basic
TIG HF Impulse DCEN welding.
. For all front panel switch pad
controls: press switch pad to
turn on light and enable
function.
NOTE: Green on nameplate indicates a TIG function (see Section
4-1 for description of controls).
ST-192 885
1
CE Models
ST-192 889
OM-2226 Page 20
3-11. Stick DCEP (Direct Current Electrode Positive) Connections
Y Turn off power before making connections.
1
Negative (–) Weld Output
Terminal
Connect work lead to negative weld
output terminal.
2
Positive (+) Weld Output
Terminal
Connect electrode holder to positive weld output terminal.
3
Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Section 3-6).
2
3
1
Ref. ST-802 471
OM-2226 Page 21
3-12. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
1
Front Panel
Correct front panel display for basic
Stick DCEP welding.
. For all front panel switch pad
controls: press switch pad to
turn on light and enable
function.
NOTE: Gray on nameplate indicates a Stick function (see Section
4-1 for description of controls).
ST-192 885
1
CE Models
ST-192 889
OM-2226 Page 22
3-13. Electrical Service Guide
NOTE
Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.
Input Voltage
Input Amperes At Rated Output
Single-Phase,
100% Duty
Cycle
Single-Phase,
60% Duty
Cycle
115
230
230
400
460
25
22
13.1
7.4
6.4
35
30
20
10
10
10
12
14
14
14
57 (17)
79 (24)
102
(31)
308
(94)
407
(124)
10
12
14
14
14
Three-Phase, 60% Duty
Cycle
Max Recommended Standard Fuse Rating In Amperes1
Normal Operating 2
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC)
1 Consult factory for circuit breaker applications.
2 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
OM-2226 Page 23
3-14. Connecting Input Power
Y Disconnect and lockout/tagout input power before connecting input conductors
from unit.
Y Have only qualified persons
make this installation.
Check input voltage available at
site.
3
1
2
1
Green Or
Green/Yellow
Line Disconnect Device
Input And Grounding
Conductors
See Section 3-13.
For three-phase operation:
Y Always connect green or
green/yellow wire to supply
grounding terminal, never to
a line terminal.
1
Connect black, white, and red wires
(L1, L2, L3) to line terminals.
1
For single-phase operation:
L1
Y Always connect green or
green/yellow wire to supply
grounding terminal, never to
a line terminal.
L2
3
L1
L2
L3
Install conductors into a deenergized line disconnect device.
Green Or
Green/Yellow
4
5
6
Y Always connect grounding
conductor first
= GND/PE
Black And White Input
Conductor
Red Input Conductor
Insulation Sleeving
Electrical Tape
Insulate and isolate red conductor
as shown.
2
Note: This unit is equipped with
Auto-Linet. The Auto-Line circuitry automatically connects to
120–460 VAC, single- or threephase power without removing the
cover to relink the power source.
2
3
4
Green or
Green/Yellow
6
5
2
input_2 3/96 - ST-802 454
OM-2226 Page 24
SECTION 4 – OPERATION
4-1. Controls
A. Non CE Units (DX/LX Model Shown)
3
1
2
6
4
5
9
10
7
8
. For all front panel switch pad controls: press
switch pad to turn on light and enable
function.
NOTE: Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
1 Encoder Control
Use encoder control in conjunction with applicable front panel function switch pads to change
values for that function. See Section 4-2.
2 Parameter Display
See Section 4-3.
3 Voltmeter
See Section 4-3.
4 Process Controls
See Section 4-4.
5 Output Controls
See Section 4-7.
To reconfigure 2T control for use as 4T, 4TE, Mini Logic control, or Spot control see Section
4-14.
6 Amperage Control
See Section 4-8.
7
Adjust Controls
See Section 4-9.
8
Power Switch
Use switch to turn unit On/Off.
9
Pulser Controls (DX And
LX Models)
See Section 4-10.
10 Sequencer Controls (DX, LX
And All CE Models)
See Section 4-11.
ST-192 885 / ST-802 452
OM-2226 Page 25
B. For CE Units (DX/LX Model Shown)
3
1
2
6
4
5
9
10
7
8
. For all front panel switch pad controls:
press switch pad to turn on light and enable function.
NOTE: Green on nameplate indicates a TIG
function, Gray indicates a Stick function.
1 Encoder Control
Use encoder control in conjunction with applicable front panel function switch pads to
change values for that function. See Section
4-2.
2 Parameter Display
See Section 4-3.
3 Voltmeter
See Section 4-3.
4 Process Controls
See Section 4-4.
5 Output Controls
See Section 4-7.
To reconfigure 2T control for use as 4T, 4TE,
Mini Logic control, or Spot control see Section 4-14.
6 Amperage Control
See Section 4-8.
7 Adjust Controls
See Section 4-9.
8 Power Switch
Use switch to turn unit On/Off.
9 Pulser Controls (DX And LX Models)
See Section 4-10.
10 Sequencer Controls (DX, LX And All
CE Models)
See Section 4-11.
ST-192 889 / ST-802 452
OM-2226 Page 26
4-2. Encoder Control
1
Encoder Control
Use control in conjunction with applicable front panel function switch
pad to set values for that function.
1
4-3. Ammeter And Volt Meter
1
1
2
Volt Meter
Displays output or open circuit voltage. If output is off, the voltmeter will
display a series of three dashes
(-––). Open circuit voltage is displayed if power is on and output is
available.
2
Parameter Display
Displays actual amperage while
welding. Meter also displays preset
parameters for any of the following
units of measure when they are active: amperage, time, percentage or
frequency. The corresponding
LED, located directly below the ammeter, will also illuminate.
4-4. Process Control
1
CE Models Only
Process Control
Press switch pad until desired process LED is illuminated:
TIG HF Impulse - This is a DCEN
(direct current electrode negative)
process with a pulsed HF (non-contact) (see Section 4-5) arc starting
method. Make connections according to Section 3-9.
1
TIG Lift-Arct - This is a DCEN (direct current electrode negative)
process in which the electrode
must come in contact with the work
piece to initiate an arc (see Section
4-5). Make connections according
to Section 3-9.
Stick (SMAW) - This is a DCEP (direct current electrode positive) process. Make connections according
to Section 3-11.
Ref. ST-192 891
OM-2226 Page 27
4-5. Lift-Arc And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
Lift-Arc Start Method
1
“Touch”
1–2
Seconds
2
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point, enable output with torch trigger, foot control, or
hand control. Hold electrode to
workpiece for 1-2 seconds, and
slowly lift electrode. Shielding gas
begins to flow when electrode
touches workpiece and arc is
formed when electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting
contaminated.
Application:
Do NOT Strike Like A Match!
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to replace the scratch method.
HF Start
When HF Start button light is On,
start arc as follows:
High frequency turns on to help
start arc when output is enabled.
High frequency turns off when arc is
started, and turns on whenever arc
is broken to help restart arc.
Application:
HF start is used for the DCEN
GTAW process when a non-contact arc starting method is required.
OM-2226 Page 28
4-6. Stick Start Procedure – Scratch Start Technique
With Stick selected, start arc as follows:
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out
electrode was lifted to high. If electrode sticks to workpiece, use a quick
twist to free it.
1
Normal open-circuit voltage is not
present before electrode touches
workpiece; only a low sensing voltage
is present between electrode and
workpiece.
2
3
OM-2226 Page 29
4-7. Output Control
CE Models Only
1
1
Output Control
Press switch pad until desired parameter LED is illuminated.
RMT STD (Remote Standard)
Torch trigger operation is as shown.
NOTE: When a foot or finger remote
control is connected to the welding
power source, initial amps, initial
slope, final slope, and final amps are
not functional.
NOTE: If a foot or finger control is connected, initial weld amperage, initial
slope, final amperage, and final slope
is controlled by the remote device, not
by the welding power source.
NOTE: If On/Off only type trigger is
used, it must be a maintained switch.
All functions become active, and must
be set by the operator.
Application: Use Remote Trigger
when the operator desires to use a
foot pedal or finger amperage control.
Current (A)
Remote (Standard) Torch Trigger Operation
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Foot Or Finger
Remote Control
Release For
Maintained Switch
Release Foot Or
Finger Remote
Control
NOTE: If arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 5-3).
OM-2226 Page 30
1 Output Control
Press switch pad until desired parameter
LED is illuminated.
RMT 2T Hold
Press switch pad to activate function.
Torch trigger operation is as shown.
NOTE: A foot or finger remote control
must be connected to the welding power
source, only trigger input is functional.
welding power source.
NOTE: Switch function can be reconfigured for 4T, 4TE, Mini Logic, or Spot control (see Section 4-14).
Application: Use Remote Trigger Hold
(2T) when long extended welds are
made. Remote Trigger Hold (2T) can help
to reduce operator fatigue.
ON
Press switch pad to activate function.
Output will be available when LED is illuminated.
NOTE: A remote contactor control is not
required.
Application: Use Output On for Stick
(SMAW) welding, or for Lift-Arc without
the use of a remote control.
NOTE: Amperage is controlled by the
Current (A)
Remote 2T Torch Trigger Operation
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release Trigger
In Less Than 3 Sec.
Push & Release Trigger.
NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode. If arc is broken
and trigger is depressed, HLP-10 will be displayed (see Section 5-3).
OM-2226 Page 31
4-8. Amperage Control
1
2
3
3
2
1
CE Models Only
3
2
1
OM-2226 Page 32
A (Amperage Control)
Encoder Control
Parameter Display
Press Amperage switch pad, and
turn Encoder control to set weld
amperage (1-200 amps). Weld amperage setting is also peak amperage when Pulser function is active
(see Section 4-10). Amperage selected is displayed on the parameter display (see Section 4-3) and
the A LED will be illuminated.
4-9. Adjust Controls (Post Flow/DIG)
1
Post Flow/DIG Control
Press switch pad until desired function LED is illuminated.
3
2
2
Encoder Control
3
Parameter Display
Post Flow - If the TIG process is
active (see Section 4-4), press
switch pad and turn encoder control
to set length of time (0–50 seconds)
gas flows after welding stops. Time
selected is displayed (see Section
4-3) and the S LED will be illuminated.
Application:
Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or
weld are dark in appearance.
1
DIG - If the Stick process is active
(see Section 4-4), press switch pad
and turn encoder control to set
amount of DIG (0-100%). When set
at 0, short-circuit amperage at low
arc voltage is the same as normal
welding amperage.
When setting is increased, shortcircuit amperage at low arc voltage
increases.
Percentage selected is displayed
(see Section 4-3) and the % LED
will be illuminated.
Application:
Control helps arc starting or making
vertical or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking
while welding.
CE Models Only
3
2
1
OM-2226 Page 33
4-10. Pulser Control (DX And LX Models)
1
3
2
CE Models Only
Pulser Control
If the Pulser is off, pressing the switch pad
will enable the pulser, and place it in the
PPS (Pulses Per Second) mode and illuminate the On and PPS LEDs. Pressing
the switch again, will first place it in the
Peak Time mode, and then in the Background Amperage Mode and illuminate the
corresponding LED. If you cycle past
Background Amps, the Pulser will shut off
and default to the Main/Peak Amperage
control. If the Pulser control is on, and you
leave to make changes to other functions,
like Peak/Main Amperage, when you return and press the Pulser switch pad, you
will start at the PPS function.
2
3
Encoder Control
Parameter Display
Turn encoder (see Section 4-2) to select
appropriate value for active pulse parameter. Value selected is displayed, and the
LED for the corresponding unit of measure, % or Hz, will be illuminated.
1
Pulser parameters are as follows:
On - When illuminated, this LED indicates
the pulser is on.
PPS (Pulse Frequency) - Ranges from
.1–500 pps (pulses per second). Control is
used to determine appearance of weld
bead.
4
Percent (%) Peak
Time Control Setting
Pulsed Output Waveforms
PPS
Balanced
(50%)
Bkg Amp
Peak Amp
Peak Time - A range of 5–95% of each
pulse cycle can be spent at the peak amperage level.
BKGND A (Background Amps) - Use
Background Amps control to set the low
pulse of the weld amperage, which cools
the weld puddle and affects overall heat input. Background Amps is set as a percentage (5-95%) of peak amperage.
4
Pulsed Output Waveforms
Example shows affect changing the Peak
Time control has on the pulsed output waveform.
More Time
At Peak
Amperage
(80%)
NOTE: Peak amperage is set using the
Amperage control (see Section 4-8). Peak
amperage (1–200 amps) is the highest
welding amperage allowed to occur in the
pulse cycle. Weld penetration varies directly with peak amperage.
Application:
More Time At
Background
Amperage
(20%)
Pulsing refers to the alternating raising and
lowering of the weld output at a specific
rate. The raised portions of the weld output
are controlled in width, height, and frequency, forming pulses of weld output.
These pulses and the lower amperage level between them (called the background
amperage) alternately heat and cool the
molten weld puddle. The combined effect
gives the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls can be adjusted while welding.
Pulsing can also be used for filler material
addition technique training.
OM-2226 Page 34
4-11. Sequencer Controls (DX, LX And All CE Models)
1
Sequencer Control
Press switch pad until desired parameter LED is illuminated. Sequencing is available only while using the TIG process, but is disabled
if a remote foot or finger control is
connected to the Remote receptacle (see Section 3-6). Sequencer
parameters cannot be selected if
the Stick process (see Section 4-4)
is active.
3
2
2
3
4
Encoder Control
Parameter Display
Turn encoder (see Section 4-2) to
set appropriate value for active sequence parameter. Value selected
is displayed on the parameter display, and the LED for the corresponding unit of measure (A, S) of
the active parameter will be illuminated.
The Sequencer parameters are as
follows:
Initial A (Initial Amperage) - Use
control to select a starting amperage (1–200 amps) that is different
from the weld amperage.
1
Application:
Initial Amperage can be used while
GTAW welding to assist in preheating cold material prior to depositing
filler material, or to ensure a soft
start.
Initial t (Initial Time)(LX Models
Only) - Use control to select 0-25
seconds of time that is needed at
the beginning of the weld.
Initial Slope t (Initial Slope Time)
Use control to select 0-25 seconds
of time that it takes to slope up/
down from initial amperage to weld
amperage. To disable, set to 0.
CE Models Only
3
4
Amperage Control
Use Amperage control (see Section 4-8) to adjust Weld Time for LX
Models only.
2
Weld Time (LX Models Only) Use control to select 0-999 seconds of time that is needed for weld
sequence.
4
Final Slope t (Final Slope Time) Use control to select 0-25 seconds
of time that it takes to slope up/
down from weld amperage to final
amperage. To disable, set to 0.
Application:
1
Final Slope should be used while
GTAW welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
Final A (Final Amperage) - Final
amperage (1-200 amps) is the amperage to which weld amperage
has sloped up/down to.
Final t (Final Time)(LX Models
Only) - Use control to select 0-25
seconds of time that is needed at
the end of the weld.
OM-2226 Page 35
4-12. Preflow Adjust (All Models)
Non CE Models Only
sel
4
00.2
2
1
3
And
Rear Panel
1 Process Control Pad
2 Adjust Control Pad
3 Power Switch
To adjust preflow, turn power off, push
and hold Process and Adjust control
switch pads, and turn On Power switch.
Hold switch pads for approximately 7
seconds (or until software version number _ _ _ _ _ _-_clears meters).
OM-2226 Page 36
Upon power up as described, the TIG
HF Impulse, Postflow, DIG, and meter S
LED will turn on, and [SEL] [0.2] will be displayed. 0.2 seconds is the factory default setting for preflow.
4
Encoder Control
Turn encoder to select from 0 to 25 sec-
onds of preflow. Value selected will be
displayed on ammeter.
Torch trigger activation or power down
will save preflow setting and exit preflow
setup.
Application:Preflow is used to purge
the immediate weld area of atmosphere.
Preflow also aids in consistent arc starting.
CE Models Only
SEL
4
00.2
2
3
1
And
Rear Panel
1
2
3
Process Control Pad
Adjust Control Pad
Power Switch
To adjust preflow, turn Off power. Push
and hold Process and Adjust control
switch pads, and turn On Power switch.
Hold switch pads for approximately 7
seconds (or until software version number _ _ _ _ _ _-_clears meters).
Upon power up as described, the TIG
Impulse, Postflow, DIG, and meter S
LED will turn on, and [SEL] [0.2] will be displayed. 0.2 seconds is the factory default
setting for preflow.
4
Encoder Control
Turn encoder to select from 0 to 25 sec-
onds of preflow. Value selected will be
displayed on ammeter.
Torch trigger activation or power down
will save preflow setting and exit preflow
setup.
Application:Preflow is used to purge
the immediate weld area of atmosphere.
Preflow also aids in consistent arc starting.
OM-2226 Page 37
4-13. Programmable TIG HF Impulse Start Amperage And Time Modes
A.
Accessing Programmable TIG Start Amperage And Time Modes (All Models)
Non CE Models Only
1
1
2
And
Rear Panel
NOTE: Before accessing programmable
TIG HF Impulse Start Amperage and Time
modes, be sure that all procedures and parameters are established. Especially, check
for proper amperage setting (see Section
4-8). Parameter adjustment is limited while
programmable TIG HF Impulse Start Am-
OM-2226 Page 38
perage and Time modes are active.
1
Process And Amperage Key Pads
2
Power Switch
To display the programmable TIG HF Impulse Start Amperage and Time screens,
turn power Off. Push and hold Process and
Amperage switch pads and turn On power
switch. Hold switch pads for approximately
7 seconds (or until software version number
_ _ _ _ _ _-_clears meters).
Proceed to Section B and/or C.
CE Models Only
1
1
2
And
Rear Panel
NOTE: Before accessing programmable
TIG HF Impulse Start Amperage and Time
modes, be sure that all procedures and parameters are established. Especially,
check for proper amperage setting (see
Section 4-8). Parameter adjustment is limited while programmable TIG HF Impulse
Start Amperage and Time modes are active.
1 Process And Amperage Key Pads
2 Power Switch
turn Off power. Push and hold Process and
Amperage switch pads and turn On power
switch. Hold switch pads for approximately
7 seconds (or until software version number _ _ _ _ _ _-_clears meters).
To display the programmable TIG HF Impulse Start Amperage and Time screens,
Proceed to Section B and/or C.
OM-2226 Page 39
B.
Setting Programmable TIG Impulse Start Amperage (All Models)
Non CE Models Only
SEL
25
2
1
NOTE: Before accessing programmable
TIG HF Impulse Start Amperage mode, be
sure that all procedures and parameters
are established. Especially, check for proper amperage setting (see Section 4-8). Parameter adjustment is limited while programmable TIG Impulse Start Amperage
mode is active.
Welding cycle can be executed while in
programmable start mode, but program parameters cannot be adjusted while in this
OM-2226 Page 40
mode.
1
Amperage Switch Pad
2
Encoder Control
and pulser functions are active, their respective LEDs will be illuminated.
To adjust TIG HF Impulse Start Amperage
proceed as follows:
The “25 ” displayed on the amps meter is
DC start amps (it is also the factory default
setting), and can be adjusted from 1 to 200
amps by turning the Encoder control.
Press Amperage switch pad. Switch pad
LED turns on, meter A LED turns on, and
[SEL] [25] is displayed on meters. TIG HF Impulse LED is on. Note: If a remote mode
To change start time, proceed to Section C.
To save changes to TIG HF Impulse Start
Amperage without changing start time, turn
power Off.
CE Models Only
SEL
25
2
1
NOTE: Before accessing programmable
TIG Impulse Start Amperage mode, be
sure that all procedures and parameters
are established. Especially, check for proper amperage setting (see Section 4-8). Parameter adjustment is limited while programmable TIG Impulse Start Amperage
mode is active.
Welding cycle can be executed while in
programmable start mode, but program parameters cannot be adjusted while in this
mode.
1
Amperage Switch Pad
2
Encoder Control
and pulser functions are active, their respective LEDs will be illuminated.
To adjust TIG Impulse Start Amperage proceed as follows:
The “25 ” displayed on the amps meter is
DC start amps (it is also the factory default
setting), and can be adjusted from 1 to 200
amps by turning the Encoder control.
Press Amperage switch pad. Switch pad
LED turns on, meter A LED turns on, and
[SEL] [25] is displayed on meters. TIG Impulse LED is on. Note: If a remote mode
To change start time, proceed to Section C.
To save changes to TIG Impulse Start Amperage without changing start time, turn
power Off.
OM-2226 Page 41
C. Setting Programmable Start Time (All Models)
Non CE Models Only
SEL
1
2
1
NOTE: Before accessing programmable
start time mode, be sure that all procedures
and parameters are established. Especially, check for proper amperage setting (see
Section 4-8). Parameter adjustment is limited while Programmable Start Time mode is
active.
Welding cycle can be executed while in
OM-2226 Page 42
programmable start mode, but program parameters cannot be adjusted while in this
mode.
1
Amperage Switch Pad
2
Encoder Control
To adjust Programmable Start Time proceed as follows:
Press Amperage switch pad. Switch pad
LED turns on, meter S LED turns on, and
[SEL] [1 ] is displayed on meters.
The [1 ] displayed on the amps meter is the
factory default setting, and can be adjusted
from 1 to 200 milliseconds by turning the
Encoder control.
To save changes, turn power Off.
CE Models Only
1
SEL
2
1
NOTE: Before accessing programmable
start time mode, be sure that all procedures
and parameters are established. Especially, check for proper amperage setting (see
Section 4-8). Parameter adjustment is limited while Programmable Start Time mode is
active.
Welding cycle can be executed while in
programmable start mode, but program parameters cannot be adjusted while in this
mode.
1
Amperage Switch Pad
2
Encoder Control
To adjust Programmable Start Time proceed as follows:
Press Amperage switch pad. Switch pad
LED turns on, meter S LED turns on, and
[SEL] [1 ] is displayed on meters.
The [1 ] displayed on the amps meter is the
factory default setting, and can be adjusted
from 1 to 200 milliseconds by turning the
Encoder control.
To save changes, turn power Off.
OM-2226 Page 43
4-14. Reconfiguring 2T For 4T, 4T Momentary, Mini Logic Control, Or Spot (DX, LX And All
CE Models)
Non CE Models Only
4
SEL
H-2
2
1
3
And
Rear Panel
1
Process Switch Pad
2
Output Switch Pad
3
Power Switch
To reconfigure 2T, turn power off. Push
and hold the Process and Output
switch pads and turn On power switch.
Hold switch pads for approximately 7
seconds (or until software version
number _ _ _ _ _ _-_clears, and display
reads [SEL] [H-2).
4
Encoder Control
Use Encoder to change functions. Ac-
OM-2226 Page 44
tive function will be displayed on amperage (right) meter.
5
Parameter Displays
The displays for the different functions
will be as shown.
Press torch trigger or turn power Off to
save setting.
Proceed to Section 4-15 for 4T, [SEL]
[H-4), operation. Sequencer option required to reconfigure for 4T.
Proceed to Section 4-16 for Mini Logic,
[SEL] [H4L), operation. Sequencer option
required to reconfigure for Mini Logic.
Proceed to Section 4-16 for 4T Momentary, [SEL] [H4E], operation. Sequencer option required to reconfigure
for 4T Momentary.
Proceed to Section 4-17 for Spot Control, [SEL] [SPO], Operation.
NOTE: After 2T has been reconfigured
and one of the reconfigured functions is
selected during normal operation, upon
power up, H-4, H4L, H4E, or SPO will be displayed for 5 seconds as a reminder to
the operator.
SEL
H-2
SEL
H-4
=
2T (See Section 4-7
for operation)
= 4T (See Section 4-15
for operation)
5
SEL
SEL
SEL
H4L
H4E
SPO
= Mini Logic (See Section 4-16
for operation)
= 4T Momentary
(See Section 4-16
for operation)
= Spot (See Section 4-17
for operation)
OM-2226 Page 45
Reconfiguring 2T For 4T, 4T Momentary, Mini Logic Control, Or Spot (DX, LX And All CE
Models) (Continued)
CE Models Only
4
SEL
H-2
2
1
And
3
V
Rear Panel
1
Process Switch Pad
2
Output Switch Pad
3
Power Switch
To reconfigure 2T, turn power off. Push
and hold the Process and Output
switch pads and turn On power switch.
Hold switch pads for approximately 7
seconds (or until software version
number _ _ _ _ _ _-_clears, and display
reads [SEL] [H-2].
4
Encoder Control
Use Encoder to change functions. Ac-
OM-2226 Page 46
tive function will be displayed on amperage (right) meter.
5
Parameter Displays
The displays for the different functions
will be as shown.
Press torch trigger or turn power Off to
save setting.
Proceed to Section 4-15 for 4T, [SEL]
[H-4), operation. Sequencer option required to reconfigure for 4T.
Proceed to Section 4-16 for Mini Logic,
[SEL] [H4L], operation. Sequencer option
required to reconfigure for Mini Logic.
Proceed to Section 4-16 for 4T Momentary, [SEL] [H4E], operation. Sequencer option required to reconfigure
for 4T Momentary.
Proceed to Section 4-17 for Spot Control, [SEL] [SPO], Operation.
NOTE: After 2T has been reconfigured
and the 2T LED is on, of the reconfigured functions is selected during normal operation, upon power up, H-4, H4L,
H4E, or SPO will be displayed for 5 seconds as a reminder to the operator.
SEL
H-2
SEL
H-4
=
2T (See Section 4-7
for operation)
= 4T (See Section 4-15
for operation)
5
SEL
H4L
SEL
H4E
SEL
SPO
= Mini Logic (See Section 4-16
for operation)
= 4T Momentary
(See Section 4-16
for operation)
= Spot (See Section 4-17
for operation)
OM-2226 Page 47
4-15. 4T Specific Trigger Method (DX, LX And All CE Models)
1
1
4T (Specific Trigger
Operation)
Sequencer is required to reconfigure for 4T.
SEL
Select 4T according to Section
4-14.
H-4
= 4T
Torch trigger operation is as shown.
While in 4T mode, there is a function available during the main weld
sequence that allows the operator
to toggle between weld current and
final current without breaking the
arc.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.
Application:
Current (A)
Torch Trigger Operation
Use 4T trigger method when the
functions of a remote current control are desired, but only a remote
on/off control is available.
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Trigger
Release
Trigger
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger
Release
Trigger
NOTE: If arc is broken and trigger is depressed, or trigger is still depressed after postflow time is complete, HLP-10 will be displayed (see
Section 5-3).
OM-2226 Page 48
4-16. Mini Logic Operation (DX, LX And All CE Models)
1
1
Mini Logic Meter Display
Sequencer option required to reconfigure for Mini Logic.
SEL
Select Mini Logic according to Section 4-14.
H4L
=
Torch trigger operation is as shown.
Mini Logic
During Mini Logic welding operation, the weld current can be
toggled between the initial amps
level and the weld amps or slope
level by pressing and releasing the
torch trigger in less than 3/4 seconds.
During Mini Logic, Final Amperage
is not available. Final slope will always slope to minimum amperage
and end the cycle.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.
Application: This ability to change
current levels without either initial
slope or final slope, gives the operator the opportunity to adjust filler
metal without breaking the arc.
Torch Trigger Operation
Weld Amps
Final Slope
Rate
Initial Slope
Final Slope
Initial Amps
Initial Amps
Final Slope
Rate
Preflow
Push & Hold
Trigger
Push & Hold
Trigger For More
Than 3/4 Sec.
Release Trigger
Postflow
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger For More
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger For More
Than 3/4 Sec.
Push And Hold
Trigger For More
Than 3/4 Sec.
NOTE: If arc is broken and trigger is depressed, or trigger is still depressed after postflow time is complete, HLP-10 will be displayed (see
Section 5-3).
OM-2226 Page 49
4-17. Spot Control Operation (All Models)
1
1
Or
SEL
SPO
Spot Function Display
Select Spot function according to
Section 4-14.
3
=
2
Spot
2
3
Amperage Switch Pad
Encoder Control
Set spot parameters as follows:
Press Amperage switch pad once
(A LED turns on) and turn Encoder
to set spot amperage.
4
Spot Time Display
Press Amperage switch pad again,
(S LED lights) and turn Encoder to
set spot time (.1–25 seconds). Factory default setting is 1 second.
Non CE Models
NOTE: While in Spot Control, Sequencer settings will be ignored,
and will not be programmable.
NOTE: While in Spot Control, when
a remote switch is connected to the
welding power source, only trigger
input is functional. Amperage is
controlled by the welding power
source.
CE Models
SPO
1.0
4
Torch trigger operation is as shown.
Application: To provide a timed
weld. Also for tacking, and thin
sheet joining.
Current (A)
Timed Spot Weld Amps
Preflow
Postflow
Push & Hold
Trigger
NOTE: If arc is broken and trigger is depressed, or trigger is still depressed after postflow time is complete, HLP-10 will be
displayed (see Section 5-3).
OM-2226 Page 50
4-18. 4T Momentary Operation (DX, LX And All CE Models)
1
4T Momentary Display
Select 4T Momentary according
to Section 4-14.
1
If unit is equipped with Sequence
Controls, a 4T Momentary trigger
method is available.
4T Momentary torch trigger operation is as shown.
H4E
SEL
=
4T Momentary While in 4T Momentary mode,
once the operator toggles out of
weld current and begins final
slope, toggling again will break
the arc and go to postflow.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.
Application:
Use 4T Momentary trigger method when the functions of a remote
current control are desired, but
only a remote on/off control is
available.
Select 4T Momentary trigger
method according to Section
4-14.
Current (A)
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release
Trigger In Less
Than 3 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode. If arc is broken
and trigger is depressed, HLP-10 will be displayed (see Section 5-3).
OM-2226 Page 51
4-19. Arc Timer/Counter Display (All Models)
Non CE Models
3/4
123
456
1
Or
1
2
V
And
Rear Panel
1
2
Output And Amperage Controls
Power Switch
To display the arc timer/counter, turn power off. Push and hold Output and Amperage control switch pads, and turn On
Power switch. Hold switch pads for
approximately 7 seconds (or until software version number
_ _ _ _ _ _-_clears displays).
OM-2226 Page 52
3 Arc Timer Display
Upon power up as described above, the
S LED will turn on, and arc time will be displayed for 5 seconds as [000 000] to [999
999]. The first four numbers indicate
hours, and the last two numbers indicate
minutes. Arc time shown in example is
read as 1,234 hours and 56 minutes. Maximum arc time is 9,999 hours and 59 minutes.
4
Arc Counter
After 5 seconds, the A LED turns on, and
the arc counter will be displayed for the
next 5 seconds as [000 000] to [999 999).
The maximum arc cycle count is 999 999.
CE Models
3/4
123
456
1
Or
1
2
V
And
Rear Panel
1
Output And Amperage Controls
2
Power Switch
To display the arc timer/counter, turn
power off. Push and hold Output and Amperage control switch pads, and turn On
Power switch. Hold switch pads for
approximately 7 seconds (or until software version number
_ _ _ _ _ _-_clears displays).
3 Arc Timer Display
Upon power up as described above, the
S LED will turn on, and arc time will be displayed for 5 seconds as [000 000] to [999
999). The first four numbers indicate
hours, and the last two numbers indicate
minutes. Arc time shown in example is
read as 1,234 hours and 56 minutes.
Maximum arc time is 9,999 hours and 59
minutes.
4
Arc Counter
After 5 seconds, the A LED turns on, and
the arc counter will be displayed for the
next 5 seconds as [000 000] to [999 999].
The maximum arc cycle count is 999 999.
OM-2226 Page 53
4-20. Lockout Functions
A. Accessing Lockout Capability
4
5
000
L–
1
6
000
And
L L1
or
2,3,4
3
2
V
Rear Panel
See Section 4-1 for explanation of controls referred to in all of
Section 4-20.
Toggle Amperage (A) switch pad to light the S LED. You may now select a lockout level.
There are four (1–4) different lockout levels. Each successive level
allows the operator more flexibility.
There are four lockout levels available. Turn Encoder control to access a lockout level (see Sections B and/or C for lockout level descriptions).
6 Lockout On
Press torch trigger or turn Off power to complete lockout On
sequence.
NOTE: Before activating lockout levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited
while lockout levels are active.
1
2
3
Amperage (A) Switch Pad
Adjust Switch Pad
Power Switch
To access lockout screens, press and hold the Amperage and Adjust
switch pads, and turn On power switch. Hold switch pads for approximately 7 seconds (or until software version number _ _ _ _ _
_-_clears displays).
4
Lockout Off
Upon power up as described, the % and Amperage (A) switch pad
LED’s light, and the display will be as shown for a lockout off condition.
5
Encoder Control
To turn On the lockout feature, proceed as follows:
Pressing Amperage (A) switch pad will toggle between the % and S
LED’s. Toggle switch pad until % LED is on.
Turn Encoder control to select a three digit lockout number. Number
will appear on the voltage (left) meter. Select any number from [001]
thru [999]. IMPORTANT: remember this three digit number, as you
will need it to turn the lockout feature off.
OM-2226 Page 54
NOTE: Setting a three digit lockout number of [000], or setting a lockout level of (L--) will cause a lockout off condition.
To turn Off the lockout feature, proceed as follows:
To access lockout screens, press and hold the Amperage (A) and
Adjust switch pads, and turn On power switch. Hold switch pads for
approximately 7 seconds (or until software version number
_ _ _ _ _ _-_clears meters).
Upon power up as described, the % and Amperage (A) switch pad
LED’s will turn on, and the meter display will be as shown for a lockout on (see callout 6) condition.
Use Encoder control to enter the same three digits that were used
to turn on the lockout feature.
Press the Amperage (A) switch pad. The % LED will turn off, and the
S LED’s will light. The amperage (right) meter display will change to
[L--). The lockout feature is now off.
NOTE: Setting a three digit lockout number of [000], or setting a lockout level of [L--] will also cause a lockout off condition.
Press torch trigger or turn Off power to complete lock out Off
sequence.
B. Lockout Levels
Level 1
Level 1
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
NOTE: Remote amperage control
is not available in level 1.
TIG Output Selection
Use Output Switch Pad To
Select A Trigger Method
For The TIG Process
If either the TIG Impulse HF or TIG
Lift Arc process (see Section 4-7)
was active when lockout level 1
was activated, the operator can
choose between RMT STD (Remote Standard) or RMT 2T HOLD
(Remote 2T Hold). The On function
is also available if TIG Lift Arc was
active.
If RMT 2T was reconfigured (see
Section 4-14) prior to lockout level
1 activation, the reconfigured output mode (4T, 4T momentary, mini
logic, or spot) is available to the operator instead of RMT 2T.
Stick Output Selection
If the Stick process was active
when lockout level 1 was activated,
the operator can choose between
RMT STD or On.
Process selection may not be
changed in lockout level 1. If the operator tries to change his process
selection, the amperage (right) meter will display [LĆ1] as a reminder.
Use Output Switch Pad To
Select A Trigger Method
For The Stick Process
Level 2
The parameters for the remaining
functions may be viewed by pressing the appropriate switch pads. If
the Encoder is turned while viewing
parameters, [LĆ1] will be displayed,
and parameters will not change. If
unit is equipped with a pulser and
the pulser is off, [LĆ1] will be displayed as a reminder that the pulser
is off.
Level 2
NOTE: Before activating lockout
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lockout levels are active.
NOTE: Remote amperage control
is not available in level 2.
Includes all the functions of level 1
plus Process Selection (see Section 4-4).
Select Stick, Or Lift-Arc,
Or HF Start
Process Selection
OM-2226 Page 55
C. Lockout Levels (Continued)
Level 3
Level 3
Use Encoder Control To
Adjust Amperage +/– 10%
Of Preset Value.
NOTE: Before activating lockout
levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited while
lockout levels are active.
NOTE: Remote amperage control is
not available in level 3.
Includes all the functions of levels 1
and 2 plus the following:
+/– 10% adjustment of preset TIG
or Stick Weld Amps
Select Stick Or TIG
+/– 10 % Amperage Adjust Control
Select desired process, TIG or
Stick, and use Encoder control to
adjust amperage +/– 10% of preset
amperage value, up to the limits of
the machine. If operator tries to go
beyond the +/– 10%, the amperage
(right) meter will display [LL3] as a reminder.
Pulser ON/Off Control
Gives operator the ability to turn on/
off the Pulser control.
Level 4
NOTE: Before activating lockout
levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited while
lockout levels are active.
Includes all the functions of levels 1,
2, and 3 plus the following:
Remote Amperage Control
Allows operator to use remote amperage control if desired. Remote
control operates from minimum to
maximum of preset amperage value. Connect remote control device
according to Section 3-6.
Turn Pulser Control On/Off
Pulser On/Off Control
Remote Amperage Control
Level 4
A
B
K
J
I
H
C L N
D M
G
E F
OM-2226 Page 56
4-21. Resetting Unit To Factory Default Settings (All Models)
1
2
3
4
Process Switch Pad
Output Switch Pad
Adjust Switch Pad
Power Switch
To reset all welding power source
functions to original factory settings,
turn power off. Push and hold the
Process, Output and Adjust switch
pads and turn On power switch.
Hold switch pads for approximately
7 seconds (or until software version
number _ _ _ _ _ _-_clears displays).
3
1
Note: In order to reset unit to factory
default settings, Lockout function
must be turned off (see Section
4-20).
2
4
CE Models
3
1
2
OM-2226 Page 57
4-22. Setting Unit To Display PPP While Pulse Welding
Non CE Models Only
5
PPP
4
sel
---
2
2
1
3
And
Rear Panel
1 Output Switch Pad
2 Pulser Switch Pad
3 Power Switch
Turn power off. Push and hold the Output and Pulser switch pads and turn On
power switch. Hold switch pads for
approximately 7 seconds (or until software version number _ _ _ _ _
_-_clears, and meters display
OM-2226 Page 58
[SEL] [Ć-- ). Upon power up as described,
the A LED under the right display and
the Pulser On LED illuminate.
4 Encoder Control
5 PPP Meter Display
Turn Encoder to change between standard and (PPP) meter display.
When the (PPP) meter display feature is
active while pulse welding, the (PPP) will
be displayed on the right meter display,
and the Meter Hold feature is disabled.
The (PPP) meter display feature will not
effect the normal amperage display or
Meter Hold capabilities when in a nonpulse welding mode.
Press torch trigger or turn off power to
save setting and end this set-up.
CE Models Only
5
PPP
4
SEL
---
2
2
1
3
And
Rear Panel
1 Output Switch Pad
2 Pulser Switch Pad
3 Power Switch
Turn power off. Push and hold the Output and Pulser switch pads and turn On
power switch. Hold switch pads for
approximately 7 seconds (or until software version number _ _ _ _ _
_-_clears, and meters display
[SEL] [Ć-- ). Upon power up as described,
the A LED under the right display and
the Pulser On LED illuminate.
4 Encoder Control
5 PPP Meter Display
Turn Encoder to change between standard and (PPP) meter display.
When the (PPP) meter display feature is
active while pulse welding, the (PPP) will
be displayed on the right meter display,
and the Meter Hold feature is disabled.
The (PPP) meter display feature will not
effect the normal amperage display or
Meter Hold capabilities when in a nonpulse welding mode.
Press torch trigger or turn off power to
save setting and end this set-up.
OM-2226 Page 59
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
. Maintain more often during severe conditions.
3 Months
Replace
unreadable
labels.
Clean and tighten
weld terminals.
Replace Damaged
Gas Hose
3 Months
Repair Or Replace
Cracked Cables
And Cords
6 Months
Y Do not remove case when
blowing out inside of unit
(see Section 5-2) .
Blow out inside. During
heavy service clean
monthly.
5-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
ST-802 451
OM-2226 Page 60
5-3. Voltmeter/Ammeter Help Displays
V
A
0
HEL
V
P-0
V
HEL
P-1
V
P-2
V
HEL
P-3
V
A
4
HEL
V
A
HEL
P-8
V
A
7
HEL
A
3
P-5
6
A
2
HEL
HEL
A
1
A
5
V
P-9
A
8
HEL
V
P10
A
9
P-4
HEL
P12
V
A
10
HEL
. All directions are in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
0 Help 0 Display
Indicates a short in the thermal protection
circuitry located on the bottom heat sink.
Contact a Factory Authorized Service
Agent if this display is shown.
1 Help 1 Display
Indicates a malfunction in the primary power circuit caused by an overcurrent condition in the primary IGBT switching circuit.
Contact a Factory Authorized Service
Agent if this display is shown.
2 Help 2 Display
Indicates an open in the thermal protection
circuitry located on the bottom heat sink.
Contact a Factory Authorized Service
Agent if this display is shown.
3 Help 3 Display
Indicates the bottom heat sink has overheated. The unit has shut down to allow the
fan to cool it (see Section 3-3). Operation
will continue when the unit has cooled.
4 Help 4 Display
Indicates an open in the thermal protection
circuitry located on the top heat sink. Contact a Factory Authorized Service Agent if
this display is shown.
5 Help 5 Display
Indicates the top heat sink has overheated.
The unit has shut down to allow the fan to
cool it (see Section 3-3). Operation will continue when the unit has cooled.
6 Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. There is a high
open circuit condition. Contact a Factory
P13
Authorized Service Agent if this display is
shown.
7 Help 9 Display
Indicates a short in the thermal protection
circuitry located on the top heat sink. Contact a Factory Authorized Service Agent if
this display is shown.
8
Help 10 Display
Indicates torch trigger is depressed. Release trigger to continue.
9 Help 12 Display
Indicates an improper set-up. You are trying
to make an adjustment that is not allowed.
10 Help 13 Display (LX Models Only)
Output enable signal broken causing weld
output to stop, but gas continues to flow if
Post Flow function is active or gas control
on 10-pin is On (see Section 3-7).
OM-2226 Page 61
5-4. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-14).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-14).
Check for proper input power connections (see Section 3-14).
No weld output; meter display On.
If using remote control, be sure correct process is enabled to provide output control at Remote 14
receptacle (see Section 3-6 as applicable).
Input voltage outside acceptable range of variation (see Section 3-13).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-3).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 3-5).
Clean and tighten all weld connections (see Section 3-5).
Fan not operating.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wandering arc
Use proper size tungsten (see Section 8).
Use properly prepared tungsten (see Section 8).
Reduce gas flow rate (see Section 3-8).
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Increase postflow time (see Section 4-1).
Check and tighten all gas fittings (see Section 3-8).
Water in torch. Refer to torch manual.
OM-2226 Page 62
SECTION 6 – ELECTRICAL DIAGRAMS
Figure 6-1. Circuit Diagram
SC-189 769-D
OM-2226 Page 63
SECTION 7 – HIGH FREQUENCY
7-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG – helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG
high_freq 12/96 – S-0693
7-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
5
6
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
OM-2226 Page 64
7-3. Correct Installation
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
9
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
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.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Metal Building Requirements
9
Metal Building Panel Bonding Methods
Bolt or weld building panels together, install
copper straps or braided wire across seams,
and ground frame.
Ground water pipes every 50 ft (15 m).
10 Windows and Doorways
7
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
11 Overhead Door Track
Ground the track.
OM-2226 Page 65
SECTION 8 – 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.
8-1. Selecting Tungsten Electrode
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC – Argon – Electrode
Negative/Straight Polarity
DC – Argon – Electrode
Positive/Reverse Polarity
AC – Argon – Using
High Frequency
AC – Argon – Balanced
Wave Using High Freq.
.010”
Up to 25
*
Up to 20
Up to 15
.020”
15-40
*
15-35
5-20
.040”
25-85
*
20-80
20-60
1/16”
50-160
10-20
50-150
60-120
3/32”
135-235
15-30
130-250
100-180
2% Thorium Alloyed
Tungsten (Red Band)
1/8”
250-400
25-40
225-360
160-250
5/32”
400-500
40-55
300-450
200-320
3/16”
500-750
55-80
400-500
290-390
1/4”
750-1000
80-125
600-800
340-525
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
8-2. Safety Information About Tungsten
1
2
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 information.
Consider using tungsten
containing ceria, lanthana,
or yttria instead of thoria.
Grinding dust from thoriated
electrodes contains low-level radioactive material.
Properly dispose of grinder
dust in an environmentally
safe way. Wear proper face,
hand, and body protection.
Keep flammables away.
1
2
Tungsten Electrode With
Balled End
Pointed Tungsten Electrode
Ref. S-0161
OM-2226 Page 66
8-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding
1
1
2
2
Tungsten Electrode
Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before welding. Do not use wheel for other jobs
or tungsten can become contaminated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1
2
1
2
Diameter of this flat determines
amperage capacity.
3
3
Stable Arc
Flat
Grinding Wheel
Grinding wheel should be dedicated to grinding tungsten only.
4
Straight Ground
1
1
2
3
Arc Wander
Point
Grinding Wheel
2
Grinding wheel should be dedicated to grinding tungsten only.
4
Ideal Tungsten Preparation – Stable Arc
4
Radial Ground
3
4
Wrong Tungsten Preparation – Wandering Arc
Ref. S-0161 / Ref. S-0162
OM-2226 Page 67
SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW)
9-1. Positioning The Torch
3
2
4
90°
1
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 information.
Consider using cerium or
lanthanum based tungsten
instead of thoriated. Thorium dust contains low-level
radioactive material. Properly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
1
Workpiece
Make sure workpiece is clean
before welding.
2
Work Clamp
Place as close to the weld as
possible.
10–15°
4
5
6
10–25°
3
4
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare
according to Section 8.
tungsten
Guidelines:
5
6
1/16 in
3/16 in
Bottom View Of Gas Cup
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
The tungsten extension should be
no greater than the inside diameter
of the gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
OM-2226 Page 68
9-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
Tilt torch
Remove rod
15°
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
OM-2226 Page 69
9-3. Positioning Torch Tungsten For Various Weld Joints
90°
Butt Weld And Stringer Bead
70°
20°
20°
“T” Joint
70°
10°
20°
20-40°
Lap Joint
70°
20°
30°
90°
Corner Joint
70°
20°
ST-162 003 / S-0792
OM-2226 Page 70
SECTION 10 – STICK WELDING (SMAW) GUIDELINES
10-1. Stick Welding Procedure
Y Weld current starts when
electrode touches workpiece.
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.
1
5
2
3
4
2
Work Clamp
Electrode
A small diameter electrode requires
less current than a large one. Follow electrode manufacturer’s
instructions when setting weld amperage (see Section 10-2).
3
6
1
Workpiece
Make sure workpiece is clean before welding.
7
4
5
6
Insulated Electrode Holder
Electrode Holder Position
Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove slag
and check weld bead before making another weld pass.
Tools Needed:
stick 12/96 – ST-151 593
OM-2226 Page 71
7014
7018
7024
Ni-Cl
308L
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
PENETRATION
EP
6011
AC
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
DC*
450
400
350
300
AMPERAGE
RANGE
250
200
150
POSITION
6013
6010
ELECTRODE
6010
&
6011
100
50
DIAMETER
ELECTRODE
10-2. Electrode and Amperage Selection Chart
MIN. PREP, ROUGH
HIGH SPATTER
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
10-3. Striking an Arc – Scratch Start Technique
1
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to workpiece, use a quick twist to free it.
2
3
S-0049
10-4. Striking an Arc – Tapping Technique
1
1
2
3
2
Electrode
Workpiece
Arc
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
3
S-0050
OM-2226 Page 72
10-5. Positioning Electrode Holder
10°-30°
90°
90°
End View of Work Angle
Side View of Electrode Angle
GROOVE WELDS
10°-30°
45°
45°
End View of Work Angle
Side View of Electrode Angle
FILLET WELDS
S-0060
10-6. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
1
2
4
3
5
S-0053-A
10-7. Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
4
5
1
2
3
4
No Overlap
Good Penetration into Base
Metal
5
S-0052-B
OM-2226 Page 73
10-8. Conditions That Affect Weld Bead Shape
NOTE
Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
Angle Too Small
Correct Angle
10° - 30°
Angle Too Large
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Short
Too Long
ARC LENGTH
Normal
Slow
Fast
TRAVEL SPEED
S-0061
10-9. Electrode Movement During Welding
NOTE
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.
1
2
1
2
3
Stringer Bead – Steady
Movement Along Seam
Weave Bead – Side to Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.
3
S-0054-A
OM-2226 Page 74
10-10. Butt Joints
1
1
2
Tack Welds
Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position before final weld.
2
Square Groove Weld
Good for materials up to 3/16 in (5
mm) thick.
3
1/16 in
(1.6 mm)
30°
Single V-Groove Weld
Good for materials 3/16 – 3/4 in
(5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
4
3
Create 30 degree angle of bevel on
materials in V-groove welding.
4
Double V-Groove Weld
Good for materials thicker than 3/16
in (5 mm).
S-0662
10-11. Lap Joint
30°
Or Less
30°
Or Less
1
1
1
2
Move electrode in circular motion.
3
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
3
2
Electrode
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
S-0063 / S-0064
10-12. Tee Joint
1
2
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
1
2
45°
Or Less
Electrode
Fillet Weld
For maximum strength weld both
sides of upright section.
2
3
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
10-9. Remove slag before making
another weld pass.
1
3
S-0060 / S-0058-A / S-0061
OM-2226 Page 75
10-13. Weld Test
1
2
3
3
Strike weld joint in direction shown.
A good weld bends over but does
not break.
3
2 To 3 in
(51-76 mm)
1/4 in
(6.4 mm)
Vise
Weld Joint
Hammer
2 To 3 in
(51-76 mm)
2
2
1
1
S-0057-B
10-14. Troubleshooting – Porosity
Porosity – small cavities or holes resulting from gas
pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
10-15. Troubleshooting – Excessive Spatter
Excessive Spatter – scattering of molten metal particles
that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
OM-2226 Page 76
10-16. Troubleshooting – Incomplete Fusion
Incomplete Fusion – failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
10-17. Troubleshooting – Lack Of Penetration
Lack Of Penetration – shallow fusion between weld metal and
base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
10-18. Troubleshooting – Excessive Penetration
Excessive Penetration – weld metal melting through base metal and
hanging underneath weld.
Excessive Penetration
Possible Causes
Excessive heat input.
Good Penetration
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-2226 Page 77
10-19. Troubleshooting – Burn-Through
Burn-Through – weld metal melting completely through base metal resulting
in holes where no metal remains.
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
10-20. Troubleshooting – Waviness Of Bead
Waviness Of Bead – weld metal that is not parallel and does not cover
joint formed by base metal.
Possible Causes
Unsteady hand.
Corrective Actions
Use two hands. Practice technique.
10-21. Troubleshooting – Distortion
Distortion – contraction of weld metal during welding that forces base
metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-2226 Page 78
Notes
OM-2226 Page 79
SECTION 11 – PARTS LIST
. Hardware
is common and
not available unless listed.
12
29
25
615
13
8
28
11
6
19
18
16
401
400
402
14
10
GROUND STUD DETAIL (5) PLACES
3
31
2
30
614
17
4
9
7
1
32
601
5
600
15
Figure 11-1. Main Assembly
OM-2226 Page 80
403
803 227
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
1 . . . . . . . . . . . . . . . . . . Fig11-2
2 . . . . . . . . . . . . . . . . . . Fig11-3
3 . . . . . . . . . . . . . . . . . . Fig11-4
4 . . . . . . . . . . . . . . . . . . Fig11-5
5 . . . . . . . . . . . . . . . . . . Fig11-7
6 . . . . . . . . S1 . . . . . . 128756
7 . . . . . . . . . . . . . . . . . . 200393
8 . . . . . . . PM1 . . . . . . 204821
9 . . . . . . . . . . . . . . . . . . 049611
10 . . . . . . . . . . . . . . . . . 196727
11 . . . . . . . . . . . . . . . . +195643
12 . . . . . . . . . . . . . . . . . 206108
13 . . . . . . . . . . . . . . . . . 195663
14 . . . . . . . . . . . . . . . . . 189782
15 . . . . . C7, 8 . . . . . 186543
16 . . . . . . . . . . . . . . . . . 189778
17 . . . . . . . . . . . . . . . . . 189773
18 . . . . . . . . . . . . . . . . . 189768
19 . . . . . . . . . . . . . . . . . 189779
25 . . . . . . . . . . . . . . . . . 189784
28 . . . . . . . . . . . . . . . . . 203990
28 . . . . . . . . . . . . . . . . . 179310
29 . . . . . . . . . . . . . . . . . 138442
30 . . . . . . . . . . . . . . . . . 185835
30 . . . . . . . . . . . . . . . . . 185836
31 . . . . . . . . . . . . . . . . . 185836
32 . . . . . . . . . . . . . . . . . 207310
400 . . . . . PC2 . . . . . . 200851
401 . . . . . PC1 . . . . . . 206129
402 . . . . PC10 . . . . . 200841
403 . . . . . . . . . . . . . . . . 199506
600 . . . . . . . . . . . . . . . . 186329
601 . . . . . . . . . . . . . . . . 083883
614 . . . . . . . . . . . . . . . . 136343
615 . . . . . . . . . . . . . . . . 200565
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
Panel, Front W/Cmpnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Rear W/Cmpnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetics Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windtunnel, W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl 3pst 40a 600vac Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . . .
Insulator, filter board (CE models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Input/Pre-Regulator Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tubing, Cop .540 Od X .123 Wall X .687 . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Power 10 Ft 12ga 4c Blk/Red/Wht/Grnyel . . . . . . . . . . . . . . . . . . .
Wrapper, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strap, Shoulder 6 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor Assy, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug W/Leads, Vfb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug W/Leads, Arc Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug W/Leads, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Lem W/Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning General Precautionary (Non Ce Models) . . . . . . . . . . . .
Label, Warning General Precautionary (Ce Models) . . . . . . . . . . . . . . . . .
Label, Caution Falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock/Exploding Parts (Non Ce Models) . . . . .
Label, Warning Electric Shock/Exploding Parts (Ce Models) . . . . . . . . .
Label, GND/PE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Core, Toroidal (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Filter (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M10–1.5x 25 Hex Hd–pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . .
Screw, K50x 20 Pan Hd–phl Stl Pld Pt Thread Forming . . . . . . . . . . . . .
Screw, M 5–.8x 35 Soc Pan hd-phl Stl Pls Sems . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
2
2
2
4
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts.
Model and serial number required when ordering parts from your local distributor.
OM-2226 Page 81
. Hardware
is common and
not available unless listed.
Ref. 199 491-A
Figure 11-2. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
11-2. Panel, Front w/Components (Figure 11-1 Item 1)
1 . . . . . . . . . . . . . . . . . . 194242
2 . . . . . . . . . . . . . . . . . . 195647
3 . . . . . . . . . . . . . . . . . . 192884
3 . . . . . . . . . . . . . . . . . . 192886
3 . . . . . . . . . . . . . . . . . . 192888
3 . . . . . . . . . . . . . . . . . . 192890
4 . . . . . . . . . . . . . . . . . . 174992
5 . . . . . . . . . . . . . . . . . . 194243
6 . . . . . . . . . . . . . . . . . . 199008
6 . . . . . . . . . . . . . . . . . . 199009
6 . . . . . . . . . . . . . . . . . . 199010
7 . . . . . . . RC1 . . . . . . 189771
8 . . . . . . . . . . . . . . . . . . 202553
9 . . . . . . . . . . . . . . . . . . 193649
9 . . . . . . . . . . . . . . . . . . 193650
11 . . . . . . . . . . . . . . . . . 185712
12 . . . . . . . . . . . . . . . . . 185713
13 . . . . . . . . . . . . . . . . . 185714
14 . . . . . . . . . . . . . . . . . 185717
15 . . . . . . . . . . . . . . . . . 185718
16 . . . . . . . . . . . . . . . . . 186228
400 . . . . . PC3 . . . . . . 208315
400 . . . . . PC3 . . . . . . 208317
. . . . . . . . . . . . . . . . . . . 186 914
OM-2226 Page 82
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
Panel, Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate/Switch Membrane, Maxstar DX & LX (Non CE Models) . . .
Nameplate/Switch Membrane, Maxstar SD (Non CE Models) . . . . . . . .
Nameplate/Switch Membrane, Maxstar DX & LX (CE Models) . . . . . . . .
Nameplate/Switch Membrane, Maxstar SD (CE Models) . . . . . . . . . . . .
Knob, Pointer .840 Dia X .250 Id W/Spring Clip–.21 . . . . . . . . . . . . . . . . .
Door, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Door Maxstar 200 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Door Maxstar 200 DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Door Maxstar 200 LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle W/Leads & Plug (14 Pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rcpt, Tw Lk Insul Fem(Dinse Type)50/70 Series Wsl . . . . . . . . . . . . . . . .
Ftg, Gas Barbed 1/4 TBG 5/8–18 Female . . . . . . . . . . . . . . . . . . . . . . . . .
Ftg, Gas Barbed 1/4 TBG 3/8–19 BSPP Male (CE Models Only) . . . . .
Insulator, Bulkhead Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Bulkhead Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Tooth 20MM I.D. X 32MM O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M20 X 1.5 1.0625 Hex .19 H Locking . . . . . . . . . . . . . . . . . . . . . . . . . .
O-Ring 0.989 I.D. X 0.070 Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-Ring 0.739 I.D. X 0.070 Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Weld Control (SD & DX Models Only) . . . . . . . . . . . .
Circuit Card Assy, Weld Control (LX Models Only) . . . . . . . . . . . . . . . . .
LED, red 5.0V 20MA RH DEC 7seg ALGAAS com anode . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
2
2
2
2
1
1
6
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
11-2. Panel, Front w/Components (Figure 11-1 Item 1) (continued)
601 . . . . . . . . . . . . . . . . 106702 . . . . Nut, 006–32 .31hex .20hex .20h Stl Pld (CE Models Only) . . . . . . . . . . 4
602 . . . . . . . . . . . . . . . . 166560 . . . . Ring, Rtng Ext .500 Shaft X .042 Thk E Style Bowed . . . . . . . . . . . . . . . 1
603 . . . . . . . . . . . . . . . . 178548 . . . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
604 . . . . . . . . . . . . . . . . 098691 . . . . Stand–off, No 6–32 X .500 Lg .250 Hex Stl M&f . . . . . . . . . . . . . . . . . . . . 4
606 . . . . . . . . . . . . . . . . 605568 . . Washer, Flat .140ID x 0.437OD x .04 (CE Models Only) . . . . . . . . . . . . . . . 4
607 . . . . . . . . . . . . . . . . 201623 . . Nut, M08-1.0 13MM Hex 4MMT Jam (CE Models Only) . . . . . . . . . . . . . . . 1
608 . . . . . . . . . . . . . . . . 602211 . . Washer, Lock .318ID x 0.586OD x .07 (CE Models Only) . . . . . . . . . . . . . . 1
609 . . . . . . . . . . . . . . . . 201624 . . Washer, Flat .342ID x .751OD (CE Models Only) . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2226 Page 83
. Hardware
is common and
not available unless listed.
Ref. 199 492
Figure 11-3.Panel, Rear w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Panel, Rear w/Components (Figure 11-1 Item 2)
1 . . . . . . . . . . . . . . . . . . 194242
2 . . . . . . . . . . . . . . . . . . 195648
3 . . . . . . . . . . . . . . . . . . 195646
3 . . . . . . . . . . . . . . . . . . 197127
4 . . . . . . . . . . . . . . . . . . 186440
4 . . . . . . . . . . . . . . . . . . 201155
5 . . . . . . . . . . . . . . . . . . 193649
5 . . . . . . . . . . . . . . . . . . 193650
6 . . . . . . . . . . . . . . . . . . 199882
. . . . . . . . . . . . . . . . . . . 146 212
. . . . . . . . . . . . . . . . . . . 073 332
600 . . . . . . . . . . . . . . . . 198245
601 . . . . . . . . . . . . . . . . 166560
601 . . . . . . . . . . . . . . . . 201623
605 . . . . . . . . . . . . . . . . 201624
606 . . . . . . . . . . . . . . . . 602211
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
Panel, Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Rear Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Rear Upper (SD & DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Rear Upper 10-pin (LX Models Only) . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Strain Relief .350/ .630 ID X1.050 Mtg Hol . . . . . . . . . . . . . . . .
Bushing, Strain Relief .450/ .709 ID X1.608 Mtg Hol (CE Models Only)
Ftg, Gas Barbed 1/4 TBG 5/8–18 Female . . . . . . . . . . . . . . . . . . . . . . . . .
Ftg, Gas Barbed 1/4 TBG 3/8–19 BSPP Male (CE Models Only) . . . . .
Receptacle, W/Leads 4 Plug 10-pin (LX Models Only) . . . . . . . . . . . . . . .
Conn, Circ Ms/Met 10Pin Sz 18 Plug Cable Solder (LX Models Only) .
Conn, Circ Ms/Met Clamp Str Rlf Sz 18 (LX Models Only) . . . . . . . . . . .
Nut, Conduit .750 Npt Pld 1.388 Od X .150 Thk . . . . . . . . . . . . . . . . . . . .
Ring, Rtng Ext .500 Shaft X .042 Thk E Style Bowed . . . . . . . . . . . . . . .
Nut, M08-1.0 13MM Hex 4MMT Jam (CE Models Only) . . . . . . . . . . . . .
Washer, Flat .342ID x .751OD .060 BRS (CE Models Only) . . . . . . . . .
Washer, Lock .318ID x 0.586OD x .07 (CE Models Only) . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2226 Page 84
. Hardware
is common and
not available unless listed.
Ref. 199 501
Figure 11-4. Magnetics Assembly w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Magnetics Assembly w/Components
(Figure 11-1 Item 3)
1 ..................
2 ..................
3 . . . . . . . FM1 . . . . . .
4 . . . . . . . GS1 . . . . . .
5 ..................
6 . . . . . . . CR1 . . . . . .
7 ..................
8 ..................
9 . . . . . . . . L2 . . . . . .
10 . . . . . . . L3 . . . . . .
11 . . . . . . . T1 . . . . . .
12 . . . . . . . . . . . . . . . . .
13 . . . . . . . . . . . . . . . . .
14 . . . . . . . . . . . . . . . . .
400 . . . . . PC7 . . . . . .
600 . . . . . . . . . . . . . . . .
195649
189785
196887
133873
197987
198549
112863
196443
189870
206020
189795
109056
196512
196514
189939
199538
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
Panel, Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Hf Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan, Muffin 24vdc 3000 Rpm 130 Cfm 4.125 Mtg Holes . . . . . . . . . . . . .
Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict . . . . . . . . . . . . . . . . . . .
Hose, Nprn Brd No 1 X .250 Id X 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay, Encl 24vdc Spst 35a/300vac 4pin Flange Mtg . . . . . . . . . . . . . . . .
Ftg, Hose Brs Barbed M 1/4 Tbg X 5/8–18 Sae Flare . . . . . . . . . . . . . . .
Choke, Output And Coupling Coil Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choke, Line 10uh 17a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil, inductor 14T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Xfmr, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . . . . .
Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Arc Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grommet, Scr No 8/10 Panel Hole .281 Sq .250 High . . . . . . . . . . . . . . .
1
1
1
1
2
1
1
1
1
1
1
2
2
2
1
4
OM-2226 Page 85
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Magnetics Assembly w/Components
(Figure 11-1 Item 3) (Continued)
603
604
609
611
612
613
614
617
................
................
................
................
................
................
................
................
057357
182737
605227
136343
099273
083147
010381
181853
....
....
....
....
....
....
....
....
Bushing, Snap–in Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . .
Screw, 010–32x2.00 Rnd Hd–slt Brs Pln . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, 750–14 Knurled1.68dia .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, K50x 20 Pan Hd–phl Stl Pld Pt Thread Forming . . . . . . . . . . . . .
Screw, 008–18x .62 Pan Hd–phl Stl Pld Sht Met A . . . . . . . . . . . . . . . . . .
Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . .
Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
1
2
4
2
1
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2226 Page 86
. Hardware
is common and
not available unless listed.
Ref. 199 494
Figure 11-5. Windtunnel w/Components
10
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-5. Windtunnel w/Components
(Figure 11-1 Item 4)
1 . . . . . . . . . . . . . . . . . . 195645
2 . . . . . . . . . . . . . . . . . . 198634
3 . . . . . . . . . . . . . . . . . . 198633
4 . . . . . . . . . . . . . . . . . . 189777
5 . . . . . . . . . . . . . . . . . . 198652
6 . . . . . . . . . . . . . . . . . +192450
7 . . . . . . . . . . . . . . . . . . 199497
8 . . . . . . . . L1 . . . . . . 189787
9 . . . . . . . . . . . . . . . . . . 199538
10 . . . . . . . C9 . . . . . . 151328
602 . . . . . . . . . . . . . . . . 154408
. . . . Panel, Midplain Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Front Heatsink Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Wind Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . Rail, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Windtunnel Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Secondary Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Choke, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Grommet, Scr No 8/10 Panel Hole .281 Sq .250 High (CE Models Only)
. . . . Capacitor, Polyp Met Film .0047Uf 1000 Vdc W/T (CE Models Only) . .
. . . . Bushing, Snap–in Nyl .562 Id X .875 Mtg Hole Cent . . . . . . . . . . . . . . . .
1
1
1
2
2
1
1
1
4
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2226 Page 87
. Hardware
is common and
not available unless listed.
199 497-B
Figure 11-6. Heat Sink, Secondary Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-6. Heat Sink, Secondary Assembly
(Figure 11-5 Item 7)
1 . . . . . . . . . . . . . . . . . . 206023 . . . . Heat Sink, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . D1 . . . . . . 204820 . . . . Kit, Diode, Ultra Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . HD1 . . . . . . 198028 . . . . Transducer, Current 100a Module Supply V+/– 15v . . . . . . . . . . . . . . . . . 1
4 . . . . . . . RT1 . . . . . . 199798 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 18 in Lead . . . . . . . . . . . . . . . . . . 1
5 . . . . . . R2, C6 . . . . 206021 . . . . Resistor/Capacitor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . R1, C5 . . . . 199138 . . . . Resistor/Capacitor, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . SR1 . . . . . . 199952 . . . . Diode, Power Module 50 Amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
600 . . . . . . . . . . . . . . . . 143360 . . . . Screw, 008–32x .50 Pan Hd–Phl Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
601 . . . . . . . . . . . . . . . . 129351 . . . . Screw, 008–32x .50 Hexwhd.34d Stl Pld Slffmg Tap–rw . . . . . . . . . . . . . 1
602 . . . . . . . . . . . . . . . . 138022 . . . . Screw, 006–32x .37 Pan Hd Phl Stl Pld Slf Fmg . . . . . . . . . . . . . . . . . . . . 1
603 . . . . . . . . . . . . . . . . 602198 . . . . Washer, Lock .141idx0.250odx.031t Stl Pld Split #6 . . . . . . . . . . . . . . . . . 1
604 . . . . . . . . . . . . . . . . 156579 . . . . Screw, 004–40x .37 Soc Hd–hex Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
605 . . . . . . . . . . . . . . . . 156580 . . . . Washer, Lock .114idx0.209odx.025t Stl Pld Split #4 . . . . . . . . . . . . . . . . . 4
606 . . . . . . . . . . . . . . . . 196683 . . . . Screw, M 6–1.0x 16 Pan Hd–phl Stl Pld Sems . . . . . . . . . . . . . . . . . . . . . 2
607 . . . . . . . . . . . . . . . . 602200 . . . . Washer, lock .168 ID x .277 OD x .04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2226 Page 88
. Hardware
is common and
not available unless listed.
199 493
Figure 11-7. Base Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-7. Base Assembly
(Figure 11-1 Item 5)
1 . . . . . . . . . . . . . . . . . . 195644 . . . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . . 019663 . . . . Mount, Nprn 15/16odx3/8rec 3/16x3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2226 Page 89
Effective January 1, 2001
(Equipment with a serial number preface of “LB” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. 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 defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure 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 a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts – 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of 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
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of 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 CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, 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, INCLUDING 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 of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions 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.
miller_warr 10/01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
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
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
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.
PRINTED IN USA
 2002 Miller Electric Mfg. Co.
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