Visit our website at

www.MillerWelds.com

OM-278

July 2004

Processes

Multiprocess Welding

163 769V

Description

Arc Welding Power Source

Dimension



652 and 812

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 parts list will then help you to decide the

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality

System Standard.

exact part you may need to fix the problem.

Warranty and service information for your 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 Electric manufactures a full line of welders and welding related equipment.

For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 7/03

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

1-1.

1-2.

1-3.

1-5.

2-1.

Symbol Usage

Arc Welding Hazards

1-4.

California Proposition 65 Warnings

Principal Safety Standards

1-6.

EMF Information

Signification des symboles

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2.

Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3.

Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil.

. . . . . . . . . . .

2-4.

Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5.

Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1.

General Precautionary Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2.

Input Connection Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3.

Electric Shock And Airflow Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4.

Nameplate Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

9

10

10

10

5

7

8

8

4

4

5

5

1

1

1

3

3

3-5.

Manufacturer’s Rating Label For CE Products

3-6.

Symbols And Definitions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

12

SECTION 4 − INSTALLATION

4-1.

4-2.

4-3.

4-4.

4-5.

4-6.

4-7.

4-8.

Specifications

Volt-Ampere Curves

Selecting A Location

Tipping

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duty Cycle And Overheating

Dimensions And Weights

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 VAC Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9.

Mig (GMAW) Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Mig (GMAW) And Flux Cored (FCAW) Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. TIG (GTAW) Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Remote 14 Receptacle RC8 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

15

16

16

17

12

12

13

13

4-13. Connecting Remote Control

4-14. Electrical Service Guide

4-15. Placing Jumper Links

4-16. Connecting Input Power

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1.

Controls (Non CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2.

Controls (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

20

21

22

17

18

19

19

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

6-1.

6-2.

6-3.

Routine Maintenance

Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Short Circuit Shutdown

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

23

24

25

25

25

25

6-4.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES

WARRANTY

26

28

30

Declaration of Conformity For

European Community (CE) Products

NOTE

This information is provided for units with CE certification (see rating label on unit.)

Manufacturer’s Name:

Manufacturer’s Address:

Miller Electric Mfg. Co.

1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product:

Dimension



812

conforms to the following Directives and Standards:

Directives

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Low Voltage Directive: 73/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/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

(April 1995 − 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:

dec_con1 10/95

Telephone:

Fax:

Mr. Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l.

Via Privata Iseo

20098 San Giuliano

Milanese, Italy

39(02)98290-1

39(02)98290-203

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _8/03

1-1.

Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

Y

Marks a special safety message.

.

Means “Note”; not safety related.

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 1-5. Read and follow all

Safety Standards.

Y

Only qualified persons should install, operate, maintain, and repair this unit.

Y

During operation, keep everybody, especially children, away.

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.

D

If earth grounding of the workpiece is required, ground it directly with a separate cable.

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

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

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.

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 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

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 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 Keep your head out of the fumes. Do not breathe the fumes.

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 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 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-278 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.

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.

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.

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.

OM-278 Page 2

1-3.

Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D

Do not install or place unit on, over, or near combustible surfaces.

D

Do not install unit near flammables.

D

Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

MOVING PARTS can cause injury.

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.

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.

OVERUSE can cause OVERHEATING

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.

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.

MOVING PARTS can cause injury.

D

Keep away from moving parts.

D

Keep away from pinch points such as drive rolls.

H.F. RADIATION can cause interference.

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.

D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

D

If notified by the FCC about interference, stop using the equipment at once.

D

Have the installation regularly checked and maintained.

D

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.

ARC WELDING can cause interference.

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.

D

To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

D

Locate welding operation 100 meters from any sensitive electronic equipment.

D

Be sure this welding machine is installed and grounded according to this manual.

D 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.

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.

1-4.

California Proposition 65 Warnings

Y

Welding or cutting equipment 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.)

Y

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

For Gasoline Engines:

Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

For Diesel Engines:

Y Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

OM-278 Page 3

1-5.

Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

(phone: 305-443-9353, website: www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.

sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway,

Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

1-6.

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:

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:

800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11

West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:

617−770−3000, website: www.nfpa.org and www. sparky.org).

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices−−phone for Region 5, Chicago, is

312−353−2220, website: www.osha.gov).

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.

OM-278 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT

UTILISATION

som_fre 8/03

2-1.

Signification des symboles

Signifie « Mise en garde. Faire preuve de vigilance. »

Cette procédure présente des risques identifiés par les symboles adjacents aux directives.

Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux

PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

Y

Identifie un message de sécurité particulier.

.

Signifie « NOTA » ; n’est pas relatif à la sécurité.

2-2.

Dangers relatifs au soudage à l’arc

Y

Les symboles ci-après sont utilisés tout au long du présent manuel pour attirer l’attention sur les dangers potentiels et les identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et suivre les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité énoncées ci-après ne font que résumer le

contenu des normes de sécurité mentionnées à la section 2-4.

Lire et respecter toutes ces normes.

Y

L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.

Y

Pendant l’utilisation de l’appareil, tenir à l’écart toute personne, en particulier les enfants.

LES DÉCHARGES ÉLECTRIQUES peuvent être mortelles.

Un simple contact avec des pièces sous tension peut causer une électrocution ou des blessures graves.

L’électrode et le circuit de soudage sont sous tension dès que l’appareil est en fonctionnement. Le circuit d’entrée et les circuits internes de l’appareil sont également sous tension.

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. Tout matériel mal installé ou mal mis à la terre présente un danger.

D Ne jamais toucher aux pièces électriques sous tension.

D

Porter des gants et des vêtements de protection secs et exempts de trous.

D

S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact physique avec la pièce ou la terre.

D

Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.

D Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.

D

Si l’utilisation d’une source de courant alternatif 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. Couper/étiqueter l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).

D

Installer et mettre à la terre correctement l’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

Pour exécuter les branchements d’entrée, fixer d’abord le conducteur de mise à la terre adéquat et contre−vérifier les connexions.

D

Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.

D

Mettre l’appareil hors tension quand on ne l’utilise pas.

D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou mal épissés.

D Ne pas s’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 d’une autre machine.

D

N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le− champ les pièces endommagées. Entretenir l’appareil conformément au présent 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 sur métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

D Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un même terminal de sortie.

Il subsiste un 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

énoncées à la section Entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

Le soudage génère des fumées et des gaz dont l’inhalation peut être dangereuse pour la santé.

D Se tenir à distance des fumées et ne pas les inhaler.

D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

D Si la ventilation est insuffisante, utiliser un respirateur à adduction d’air agréé.

D

Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent se substituer à l’air, abaisser la teneur en oxygène et causer des lésions ou des accidents mortels. S’assurer que l’air est respirable.

D Ne pas souder 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.

D

Ne pas souder de métaux munis d’un revêtement, tels que la tôle d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.

OM-278 Page 5

LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.

Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.

Des étincelles sont projetées pendant le soudage.

D

Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).

D

Porter des lunettes de sécurité à écrans latéraux sous le masque.

D

Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat

éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder l’arc.

D Porter des vêtements de protection en matière durable et ignifuge

(cuir ou laine) et des chaussures de sécurité.

LE SOUDAGE peut causer un incendie ou une explosion.

Le soudage effectué sur des récipients fermés tels que des réservoirs, des fûts ou des conduites peut causer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, les pièces chaudes et les équipements chauds peuvent causer des incendies et des brûlures. Le contact accidentel de l’électrode avec tout objet métallique peut causer 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 protéger les tiers de la projection d’étincelles et de métal chaud.

D

Ne pas souder à un endroit où des étincelles peuvent tomber sur des substances inflammables.

D Placer 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 agréées.

D

Des étincelles et des matières en fusion peuvent facilement passer même par des fissures et des ouvertures de petites dimensions.

D

Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

D

Le soudage effectué sur un plafond, un plancher, une paroi ou une cloison peut déclencher un incendie de l’autre côté.

D

Ne pas souder des récipients fermés tels que des réservoirs, des fûts ou des conduites, à moins qu’ils n’aient été préparés conformément à l’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 que le courant ne circule sur une longue distance, par des chemins inconnus, et ne cause 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 porte−

électrode ou couper le fil au raz du tube−contact.

D Porter des vêtements de protection exempts d’huile tels que des gants en cuir, une chemise en tissu épais, des pantalons sans revers, des chaussures montantes et un masque.

D

Avant de souder, retirer tout produit combustible de ses poches, tel qu’un briquet au butane ou des allumettes.

LES PARTICULES PROJETÉES peuvent blesser les yeux.

l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du laitier.

D Le soudage, le burinage, le passage de la pièce à la brosse métallique et le meulage provoquent

D Porter des lunettes de sécurité à écrans latéraux agréés, même sous le masque de soudage.

LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même la mort.

D

Couper l’alimentation en gaz protecteur en cas de non utilisation.

D Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.

LES PIÈCES CHAUDES peuvent causer des brûlures graves.

D

Ne pas toucher les pièces chaudes à main nue.

D Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche.

LES CHAMPS MAGNÉTIQUES peuvent perturber le fonctionnement des stimulateurs cardiaques.

D Les personnes qui portent un stimulateur cardiaque doivent se tenir à distance.

D

Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

Le bruit de certains processus et équipements peut affecter l’ouïe.

D Porter des protecteurs d’oreille agréés si le niveau sonore est trop élevé.

Les BOUTEILLES endommagées peuvent exploser.

Les bouteilles de gaz protecteur contiennent du gaz sous haute pression. Toute bouteille endommagée peut exploser. Comme les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

D

Protéger les bouteilles de gaz comprimé de la chaleur excessive, des chocs mécaniques, du laitier, des flammes nues, 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 poser une torche de soudage sur une bouteille de gaz.

D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.

D Ne jamais souder une bouteille contenant du gaz sous pression − elle risquerait d’exploser.

D

N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et raccords adéquats pour l’application envisagée ; les maintenir en bon

état, ainsi que les pièces connexes.

D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.

D

Laisser le capuchon protecteur 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 de la CGA, mentionnées dans les normes de sécurité.

OM-278 Page 6

2-3.

Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil.

Risque D’INCENDIE OU D’EXPLO-

SION

D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.

D Ne pas installer l’appareil à proximité de produits inflammables.

D

Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.

LA CHUTE DE L’APPAREIL peut blesser.

D

N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de gaz ou tout autre accessoire.

D

Utiliser un engin de capacité adéquate pour lever l’appareil.

D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

L’EMPLOI EXCESSIF peut FAIRE

SURCHAUFFER L’ÉQUIPEMENT.

D

Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.

D

Réduire le courant ou le cycle opératoire avant de reprendre le soudage.

D

Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les circuits imprimés.

D

Mettre un bracelet antistatique 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 imprimés.

LES PIÈCES MOBILES peuvent causer des blessures.

D Se tenir à l’écart des pièces mobiles.

D

Se tenir à l’écart des points de coincement tels que les dévidoirs.

LES FILS DE SOUDAGE peuvent causer des blessures.

D

Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction.

D Ne pas diriger le pistolet vers soi, vers d’autres personnes ou vers toute pièce mécanique en engageant le fil de soudage.

LES ORGANES MOBILES peuvent causer des blessures.

D Se tenir à l’écart des organes mobiles comme les ventilateurs.

D

Maintenir fermés et bien fixés les portes, panneaux, recouvrements et dispositifs de protection.

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H. F.) risque de causer des interférences.

D

Le rayonnement haute fréquence peut causer des interférences avec les équipements de radionavigation et de communication, les services de sécurité et les ordinateurs.

D

Ne demander qu’à des personnes qualifiées familiarisées avec les

équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences causées par l’installation.

D

Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.

D Faire régulièrement contrôler et entretenir l’installation.

D

Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.

LE SOUDAGE À L’ARC peut causer des interférences.

D L’énergie électromagnétique peut causer des interférences avec l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

D

Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.

D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (par ex. : à terre).

D

Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

D

Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.

D

En cas d’interférences après exécution des directives 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-278 Page 7

2-4.

Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

(téléphone : (305) 443−9353, site Web : www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS

F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL

33126 (téléphone : (305) 443−9353, site Web : www.aws.org).

National Electrical Code, norme NFPA 70, de la National Fire Protection

Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1, de la Compressed Gas Association, 1735 Jefferson Davis Highway,

Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900, site Web : www.cganet.com).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)

463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).

Practice For Occupational And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute, 11 West

42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900, site Web : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, norme NFPA 51B, de la National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a

10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)

353−2220, site Web : www.osha.gov).

2-5.

Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme

En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent préoccupants. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs magnétiques et aux champs électriques à haute fréquence constitue un risque pour la santé humaine ». Toutefois, les études et l’examen des preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs

électromagnétiques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

4. Garder le poste de soudage et les câbles le plus loin possible de soi.

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.

OM-278 Page 8

SECTION 3 − DEFINITIONS

3-1.

General Precautionary Label

Warning! Watch Out! There are possible hazards as shown by the symbols.

1 Electric shock from welding electrode or wiring can kill.

1.1 Wear dry insulating gloves.

Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

1.2 Protect yourself from electric shock by insulating yourself from work and ground.

1.3 Disconnect input plug or power before working on machine.

2 Breathing welding fumes can be hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust to remove the fumes.

2.3 Use ventilating fan to remove fumes.

3 Welding sparks can cause explosion or fire.

3.1 Keep flammables away from welding. Do not weld near flammables.

3.2 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

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.

OM-278 Page 9

3-2.

Input Connection Label

1/96 1 2

1

5

?

V

?

A

2

ÍÍ

ÍÍ

6 7 8

3

3

?

V

ÍÍÍÍ

ÍÍÍÍ

3

ÍÍÍÍ

4

5

9

4

S-179 290

1 Warning! Watch Out! There are possible hazards as shown by the symbols.

2 Electric shock from wiring can kill.

3 Disconnect input plug or power before working on machine.

4 Read the Owner’s Manual before working on this machine.

5 Consult rating label for input power requirements, and check power available at the job site − they must match.

6 Read Owner’s Manual and inside labels for connection points and procedures.

7 Move jumper links as shown on inside label to match voltage at job site.

8 Having a loop of extra length, connect grounding conductor first.

9 Connect line input conductors as shown on inside label − double-check all connections, jumper link positions, and input voltage before applying power.

3-3.

Electric Shock And Airflow Label

1 2 3

S-179 563

1 Warning! Watch Out! There are possible hazards as shown by the symbols.

2 Electric shock from wiring and exposed weld terminals can kill.

3 Close door before turning on unit.

1/96

3-4.

Nameplate Safety Symbols

1 1

2 3 4

5 6

1 Warning! Watch Out! There are possible hazards as shown by the symbols.

2 Electric shock from welding electrode or wiring can kill.

3 Sparks from arcing electrode can cause explosion or fire − disconnect cable for process not in use.

4 Read Owner’s Manual for connection procedures.

5 Electric shock from wiring can kill.

6 Disconnect input power before working on unit or making terminal strip connections.

Nameplate D-179 389

OM-278 Page 10

3-5.

Manufacturer’s Rating Label For CE Products

.

For label location

see Section 4-4.

S-174 343

OM-278 Page 11

3-6.

Symbols And Definitions

NOTE

A

Amperes

Temperature

Output

Positive High Inductance Weld

Output Terminal

On

Some symbols are found only on CE products.

U

0

I

1

IP

S

Rated No Load

Voltage (Average)

Primary Current

Degree Of

Protection

Suitable For Areas

Of Increased

Shock Hazard

U

1

I

2

Amperage/Voltage

Control−Panel

Wire Feeder

Circuit Breaker

Positive Low Inductance Weld

Output Terminal

Off

Primary Voltage

Rated Welding

Current

Three-Phase

Protective Earth

(Ground)

Gas Tungsten Arc

Welding (GTAW)

Arc Force (DIG)

Remote

Negative Weld

Output Terminal

Percent

Shielded Metal Arc

Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

V

Volts

Input

Direct Current

U

2

Conventional Load

Voltage

X

Duty Cycle

S

1

KVA

Line Connection

Three-Phase

Transformer

Rectifier

Hz

Hertz

SECTION 4 − INSTALLATION

4-1.

Specifications

Rated

Output

Amperage/

Range DC

650 A @ 44

Cycle

50 − 815 A

In CC Mode

10 − 65 V In

CV Mode

*While idling

( ) Indicates specification differences for CE models

72 (70) VDC

In

CC Mode

70 (66) VDC

In

CV Mode

230

V

Amperes Input at Rated Load Output,

50 or 60 Hz, Three-Phase

380

V

400

V

440

V

460

V

520

V

575

V

126 77 73 66 63 54 50.4

KVA

50

KW

34.8

OM-278 Page 12

4-2.

Duty Cycle And Overheating

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

Y

Exceeding duty cycle can damage unit and void warranty.

100% Duty Cycle

Overheating

4-3.

Volt-Ampere Curves

Continuous Welding

0

Minutes

15

A. *CC Mode

A/V

OR

Reduce Duty Cycle duty1 4/95 / Ref. SA-168 918

Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown.

*High inductance connection.

B. CV Mode

va_curve1 − 4/95 − ST-168 916 / ST-168 917

OM-278 Page 13

4-4.

Selecting A Location

Movement

1

OR

Location And Airflow

3

4

18 in

(460 mm)

6

2

18 in

(460 mm)

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to move unit.

If using lifting forks, extend forks beyond opposite side of unit.

3 Rating Label (Non CE Models

Only)

Use rating label to determine input power needs. Label located under front access door.

4 Plate Label (CE Models Only)

Label located under front access door.

5 Rating Label (CE Models

Only)

Use rating label to determine input power needs. Label located on rear access door

(see Section 3-5).

6 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.

5

OM-278 Page 14

4-5.

Dimensions And Weights

B

G

E

Front

C

A

H

800 453-A / 801 530

A 30 in (762 mm) Including lift eye

B 23 in (584 mm)

C

38 in (965 mm) Including strain relief

D 35 in (889 mm)

E 1-1/4 in (32 mm)

F 21-1/8 in (537 mm)

G 1-1/8 in (29 mm)

H 7/16 in (11 mm) Dia

Weight

545 lb (247 kg)

OM-278 Page 15

4-6.

Tipping

Y

Be careful when placing or moving unit over uneven surfaces.

4-7.

115 VAC Receptacle And Circuit Breakers

3

2

1

Y

Turn Off power before connecting to receptacle.

1 115 V 15 A AC Receptacle

RC9

Power is shared between RC9 and

Remote 14 receptacle RC8 (see

Section 4-13).

2 Circuit Breaker CB1

3 Circuit Breaker CB2

CB1 protects the 115 volts ac portion of RC8 and RC9 from overload.

CB2 protects the 24 volts ac portion of RC8 and Remote Power On/Off from overload.

Press button to reset breaker.

Ref. ST-800 166-D

OM-278 Page 16

4-8.

Weld Output Terminals And Selecting Cable Sizes

Y

ARC WELDING can cause Electromagnetic Interference.

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.

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Y

Turn Off power before connecting to weld output terminals.

Welding

Amperes

10 − 60%

Duty

Cycle

60 − 100%

Duty Cycle

10 − 100% Duty Cycle

Low

100

150

200

250

300

350

400

4

3

3

2

1

1/0

1/0

4

3

2

1

1/0

2/0

2/0

4

2

1

1/0

2/0

3/0

3/0

3

1

1/0

2/0

3/0

4/0

4/0

2

1/0

2/0

3/0

4/0

2-2/0

2-2/0

1

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

1/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

500

600

700

800

2/0

3/0

4/0

4/0

3/0

4/0

2-2/0

2-2/0

4/0

2-2/0

2-3/0

2-3/0

2-2/0

2-3/0

2-4/0

2-4/0

2-3/0

2-4/0

3-3/0

3-4/0

2-4/0

3-3/0

3-4/0

3-4/0

3-3/0

3-4/0

3-4/0

4-4/0

3-3/0

3-4/0

4-4/0

4-4/0

*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. Contact your distributor for the mm 2 equivalent weld cable sizes.

S-0007-E

1/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

4-9.

Mig (GMAW) Cable Connections

Gas Flowmeter/

Regulator

HIGH

INDUCTANCE

LOW

INDUCTANCE

Y

Turn Off power before making connections.

Polarity: For Electrode Positive (DCEP), connect weld cables as shown. For

Electrode Negative (DCEN), typical for

Gasless Flux Cored Welding, reverse cable connections at welding power source.

NOTE: For better performance for most GMAW (DCEP and DCEN) applications, it is recommended that weld output connections be made to the Low Inductance weld output terminal.

+ + or

−

Rear Of

Wire Feeder

OM-278 Page 17

4-10. Mig (GMAW) And Flux Cored (FCAW) Cable Connections

GMAW / FCAW

HIGH

INDUCTANCE

LOW

INDUCTANCE

(Gasless FCAW)

+ +

Y

Turn Off power before making connections.

For better performance for most GMAW and

(gas shielded) FCAW (DCEP) applications, it is recommended that weld output connections be made to the Low Inductance weld output terminal. Make connections as shown.

or

−

Rear Of

Wire Feeder

Gas Flowmeter/

Regulator

Y

Turn Off power before making connections.

For better performance for most Gasless Flux

Cored FCAW (DCEN) applications, it is recommended that weld output connections be made to the Low Inductance weld output terminal.

Make connections as shown.

OM-278 Page 18

FCAW (Gasless)

LOW

INDUCTANCE

(Gasless FCAW)

+ + −

Rear Of

Wire Feeder

4-11. TIG (GTAW) Cable Connections

Gas Flowmeter/

Regulator

HIGH

INDUCTANCE

+

Y

Turn Off power before making connections.

For better performance for most GTAW applications, it is recommended that electrode negative (DCEN) weld output connections be made to the high Inductance weld output terminal. Make connections as shown.

+ −

Optional HF Unit

4-12. Remote 14 Receptacle RC8 Information

REMOTE OUTPUT CONTROL

GND

J

K

G

H

I

*

*

*

*

Socket

A

B

C

D

E

F

Information

24 volts ac. Protected by circuit breaker CB2.

Contact closure to A completes 24 volts ac contactor control circuit.

Command reference; 0 to +10 volts dc (CC), +10 volts dc (CV).

Remote control circuit common.

0 to +10 volts dc input command signal from remote control.

Current feedback; 1 volt per 100 amperes.

Voltage feedback; 1 volt per 10 arc volts.

115 volts, 15 amperes, 60 Hz ac. Protected by circuit breaker CB1.

Contact closure to I completes 115 volts ac contactor control circuit.

Chassis common.

Circuit common for 24 and 115 volts ac circuits.

Voltage sensing signal from Negative (−) weld output terminal.

Voltage sensing signal from Positive (+) weld output terminal.

* Not Used

OM-278 Page 19

4-13. Connecting Remote Control

Y

Turn off power before connecting a remote control.

1 Remote 14 Receptacle RC8

Connect remote control to RC8.

B

A

K

J

I

C

L

D M

N

E F

G

H

1

OR OR

Ref. ST-800 166-D / Ref. S-0004-A / S-0750

4-14. Electrical Service Guide

Input Voltage

Input Amperes At Rated Output

Max Recommended Standard Fuse Rating In Amperes

1

Time-Delay

2

Normal Operating 3

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

230

126

150

200

1

208

(64)

6

60 Hz Models

460

63

70

90

6

328

(100)

8

575

50.4

60

80

6

513

(156)

8

380

77

90

125

4

335

(102)

6

50 Hz Models

400

73

90

110

4

371

(113)

6

440

66

80

100

4

449

(137)

8

520

54

60

80

6

419

(128)

8

Reference: 1999 National Electrical Code (NEC)

1 Consult factory for circuit breaker applications.

2 “Time-Delay” fuses are UL class “RK5” .

3 “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-278 Page 20

4-15. Placing Jumper Links

Y

Disconnect and lockout/tagout input power before installing or moving jumper links.

Check input voltage available at site.

1 Jumper Link Label

Check label − only one is on unit.

2 Jumper Links

Move jumper links to match input voltage.

Close and secure access door, or

go on to Section 4-16.

230 VOLTS

1

220 VOLTS

(FACTORY OPTION)

380 VOLTS

380 VOLTS

460 VOLTS

400 VOLTS

575 VOLTS

Ref. S-174 973-A

440 VOLTS

Ref. S-174 975-A

520 VOLTS

2

Tools Needed:

3/8 in

3/8 in

Do not overtighten jumper link nuts.

Ref. ST-800 103-A

OM-278 Page 21

4-16. Connecting Input Power

3

9

= GND/PE Earth Ground

8

11

10

2

4

7

1

IMPORTANT

6

3

Input Contactor

7

L1 (U)

L2 (V)

L3 (W)

4

5

4

3

=

GND/ PE Earth Ground

Tools Needed:

3/8 in

3/8 in

Y

Installation must meet all National and Local Codes − have only qualified persons make this installation.

Y

Disconnect and lockout/tagout input power before connecting input conductors from unit.

Y

Make input power connections to the welding power source first.

Y

Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.

See rating label on unit and check input voltage available at site.

3 Input Power Conductors (Customer

Supplied Cord)

Select size and length of conductors using

Section 4-14. Conductors must comply

with national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size.

Welding Power Source Input Power

Connections

4 Strain Relief

Route conductors (cord) through strain relief and tighten screws.

5 Machine Grounding Terminal

6 Green Or Green/Yellow Grounding

Conductor

7 Reed Switch (Ground Current

Sensor) (Optional)

Connect green or green/yellow grounding conductor to welding power source grounding terminal first. If unit is equipped with optional ground current sensor, route grounding conductor through reed switch two times and connect to grounding terminal.

8 Welding Power Source Line

Terminals

9 Input Conductors L1 (U), L2 (V) And

L3 (W)

Connect input conductors L1 (U), L2 (V) and L3 (W) to welding power source line terminals.

Close and secure access door on welding power source.

Disconnect Device Input Power Connections

10 Disconnect Device (switch shown in

OFF position)

11 Disconnect Device (Supply)

Grounding Terminal

Connect green or green/yellow grounding conductor to disconnect device grounding terminal first.

12 Disconnect Device Line Terminals

Connect input conductors L1 (U), L2 (V)

And L3 (W) to disconnect device line terminals.

13 Over-Current Protection

Select type and size of over-current

protection using Section 4-14 (fused dis-

connect switch shown).

Close and secure door on line disconnect device. Remove lockout/tagout device, and place switch in the On position.

800 103-C / Ref. 801 116-A

OM-278 Page 22

SECTION 5 − OPERATION

5-1.

Controls (Non CE Models)

3

1 2

4

8 7

6 5

Ref. ST-184 939

1 Arc Force (Dig) Control

Control increases SMAW short-circuit amperage which allows the operator to use a very short arc length without sticking the electrode.

Set control at 0 for normal welding amperage and GTAW applications. Turn clockwise to increase short-circuit amperage.

2 Process Selector Switch

•

GMAW Mode: For use with flux Cored

(FCAW) or submerged arc (SAW) applications.

•

SMAW (Hot Start On) Mode: Hot Start is energized for Stick (SMAW). When Hot

Start is energized, higher short circuit amperage aids in arc starting. NOTE: use the

Positive (+) High Inductance weld output

terminal (see Section 4-8).

•

SMAW (Hot Start Off) Mode: For use with

TIG (GTAW), scratch start only, or submerged arc (SAW) applications. NOTE: for GTAW, use the Positive (+) High Inductance weld output terminal (see Section

4-8).

3 Amperage/Voltage Adjustment Control

When Process Selector switch is in the

SMAW/GTAW position, turn control clockwise to increase amperage. Read amperage from outer scale of control. When Process

Selector switch is in the GMAW position, turn control clockwise to increase voltage. Voltmeter value changes as control knob is turned. Control can be adjusted while welding.

4 Digital Meters

With Process Selector switch in the SMAW/

GTAW position, digital meters will read 0

(zero) with contactor off. Digital meters will display actual output voltage and amperage with contactor on.

With Process Selector switch in the GMAW position, voltmeter displays preset voltage with contactor off. Voltmeter and ammeter display actual output voltage and amperage with contactor on.

5 Power Switch With Indicator Light

6 High Temperature Shutdown Light

7 Remote Amperage/Voltage Control

Switch

For front panel control, place switch in Panel position. For remote control, place switch in

Remote position, and connect remote de-

vice (see Section 4-13).

8 Output Switch (Contactor)

For front panel control of output, place switch in Panel position. For remote control of output, place switch in Remote position, and connect remote device (see

Section 4-13).

Y Weld output studs are energized only when Output switch is in On position, or while welding.

Y

Turn Off power before connecting remote device.

OM-278 Page 23

5-2.

Controls (CE Models)

1 2

3 4

8 7

6 5

Ref. ST-184 936

1 Arc Force (Dig) Control

Control increases SMAW short-circuit amperage which allows the operator to use a very short arc length without sticking the electrode.

Set control at 0 for normal welding amperage and GTAW applications. Turn clockwise to increase short-circuit amperage.

2 Process Selector Switch

•

GMAW Mode: For use with flux Cored

(FCAW) or submerged arc (SAW) applications.

•

SMAW (Hot Start On) Mode: Hot Start is energized for Stick (SMAW). When Hot

Start is energized, higher short circuit amperage aids in arc starting. NOTE: use the

Positive (+) High Inductance weld output

terminal (see Section 4-8).

•

SMAW (Hot Start Off) Mode: For use with

TIG (GTAW), scratch start only, or submerged arc (SAW) applications. NOTE: for GTAW, use the Positive (+) High Inductance weld output terminal (see Section

4-8).

3 Amperage/Voltage Adjustment Control

When Process Selector switch is in the

SMAW/GTAW position, turn control clockwise to increase amperage. Read amperage from outer scale of control. When Process

Selector switch is in the GMAW position, turn control clockwise to increase voltage. Voltmeter value changes as control knob is turned. Control can be adjusted while welding.

4 Digital Meters

With Process Selector switch in the SMAW/

GTAW position, digital meters will read 0

(zero) with contactor off. Digital meters will display actual output voltage and amperage with contactor on.

With Process Selector switch in the GMAW position, voltmeter displays preset voltage with contactor off. Voltmeter and ammeter display actual output voltage and amperage with contactor on.

5 Power Switch With Indicator Light

6 High Temperature Shutdown Light

7 Remote Amperage/Voltage Control

Switch

For front panel control, place switch in Panel position. For remote control, place switch in

Remote position, and connect remote de-

vice (see Section 4-13).

8 Output Switch (Contactor)

For front panel control of output, place switch in Panel position. For remote control of output, place switch in Remote position, and connect remote device (see

Section 4-13).

Y

Weld output studs are energized only when Output switch is in On position, or while welding.

Y Turn Off power before connecting remote device.

OM-278 Page 24

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

6-1.

Routine Maintenance

Y

Disconnect power before maintaining.

3 Months

Replace unreadable labels.

Repair or replace cracked weld cable.

Clean and tighten weld terminals.

6 Months

Blow out or vacuum inside.

During heavy service, clean monthly.

OR

6-2.

Fuse F1

1

Y

Disconnect and lockout/tagout input power before checking or changing fuse.

1 Fuse F1 (See Parts List For

Rating)

Fuse F1 protects control transformer from overload. If F1 opens, weld output and fan motor stops. Replace F1.

Close and secure access door.

Tools Needed:

3/8 in

Ref. ST-800 101-C

6-3.

Short Circuit Shutdown

When contact tip is shorted and sticks to workpiece, the unit output falls to a safe operating level. To resume operation, release gun trigger, turn Off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged.

Turn On unit to continue operation.

OM-278 Page 25

6-4.

Troubleshooting

Trouble Remedy

No weld output; unit completely inoperative; pilot light PL1 off.

Place line disconnect device in On position (see Section 4-16).

Check for open line fuse(s), and replace if open (see Section 4-16).

Check for proper input power connections (see Section 4-16).

Check for proper jumper link position (see Section 4-15).

Check fuse F1, and replace if necessary (see Section 6-2).

Unit overheated. Allow unit to cool with fan On (see Section 4-2).

No weld output; power switch pilot light on.

Limited weld output and low open-circuit voltage.

Check for open line fuse(s), and replace if open (see Section 4-16).

Check for proper input power connections (see Section 4-16).

Check for proper jumper link position (see Section 4-15).

Clean and tighten all weld output connections.

Have Factory Authorized Service Agent check control board PC1 and hall device HD1.

Unit provides only maximum or minimum weld output.

Not able to obtain minimum output in

CC mode.

Erratic or improper weld output.

Check position of Remote Amperage/Voltage Control switch (see Section 5-1).

Use high inductance weld output terminal when in CC mode to obtain minimum output (see Section

4-8).

Use proper size and type of weld cable (see Section 4-8).

Clean and tighten all weld connections.

Check wire feeder installation according to Owner’s Manual.

Check position of Process selector switch (see Section 5-1).

Have Factory Authorized Service Agent check control board PC1 and hall device HD1.

Reset circuit breaker CB1 (see Section 4-7).

No 115 volts ac output at duplex receptacle, or Remote 14 receptacle.

No 24 volts ac output at Remote 14 receptacle.

Fan not operating. Note: fan only runs when cooling is necessary.

Reset circuit breaker CB2 (see Section 4-7).

Check for and remove anything blocking fan movement.

Wandering arc; poor control of arc direction.

Have Factory Authorized Service Agent check fan motor.

Reduce gas flow rate.

Select proper size tungsten.

Properly prepare tungsten.

Shield weld zone from drafts.

Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

If using remote control, place Output (Contactor) switch in Remote 14 position, and connect remote

control (see Sections 4-12 and 4-13). If remote is not being used, place switch in On position (see

Section 5-1).

Check, repair, or replace remote control.

Check for proper input power connections (see Section 4-16).

Check for open line fuse(s), and replace if open, or reset circuit breaker (see Section 4-16).

Turn power switch off then back on. If no output condition remains, have Factory Authorized Service agent check SCR’s.

Check position of Remote Amperage/Voltage Control switch (see Section 5-1).

Digital meter not working properly.

Increase postflow time.

Check and tighten all gas fittings.

Properly prepare tungsten.

Check for water in torch, and repair torch if necessary. See torch Owner’s Manual.

Have Factory Authorized Service Agent check control board PC1 and connections, and replace if necessary.

OM-278 Page 26

Notes

OM-278 Page 27

SECTION 7 − ELECTRICAL DIAGRAM

OM-278 Page 28

Figure 7-1. Circuit Diagram

218 514-A

OM-278 Page 29

.

Hardware is common and not available unless listed.

SECTION 8 − PARTS LIST

OM-278 Page 30

Figure 8-1. Main Assembly (652 Model Illustrated)

ST-800 703-F

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 8-1. Main Assembly (652 Model Illustrated)

. . . 1 . . . . . . . . . . . . . . . . . .

. . . 2 . . . . . . . . . . . . . . . . . . .

+179 432

179 431

. . .

. . .

. . .

. . .

3

4

5

6

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

164 700

162 816

162 820

162 830

. . . . . . . . . . . . . . . . . . . . . . . . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

7

8

9

11

12

13

13

13

14

15

16

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . .

. . . . . . . . . . . .

. . . . . . . .

. . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . .

HD1

PLG14

Z1

C21-23

T2

T2

T2

TE1

. . . . . .

. . . . .

. . . 10 . . . . . . . . . . . . . . . . . . .

. . . . . . .

. . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

604 536

177 279

173 605

168 829

115 094

164 717

180 068

163 906

159 042

159 043

177 264

159 244

601 835

038 887

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

PANEL, side

COVER, top

BAFFLE, air

CHANNEL, upright

BAR, mtg lift eye

LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCREW, .312-18 x 1.750hexhd gr 5

GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRACKET, mtg LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSDUCER, current 1000A module

CONNECTOR & SOCKETS

BUS BAR, stab jumper

STABILIZER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAPACITOR, 50 and 60Hz

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

. .

. .

TRANSFORMER, control 50VA 24V 230/460/575 (60Hz)

TRANSFORMER, control 50VA 24V 380/400/440 (50Hz)

TRANSFORMER, control 50VA 24V 380/520 (50Hz)

. . . . . . .

. . . . . . .

. . . . . . . . . . .

. . PRIMARY BOX, (consisting of)

. . . . NUT, 10-32 brs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . STUD, pri bd brs 10-32 x 1.375

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

24

24

1

1

1

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 17 . . . . . . . . . . . . . . . . . . .

. . . 18 . . . . . . . . . . . . . . . . . . . .

. . . 19 . . . . . . . . F1 . . . . . .

038 618

010 913

601 835

159 034

Fig 8-4

*156 065

. .

. .

. .

. .

. .

. .

LINK, jumper term bd pri

WASHER, flat .218 ID brs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

24

24

HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUSE, crtg .5A 600V time delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

1

1

3

1

1

1

1

2

1

2

1

2

4

2

1

. . .

. . .

20

21

. . . . . . . .

. . . . . . .

W

CR4

. . . . . . .

. . . . .

160 794

♦

140 750

. . . 22 . . . . . . . . . . . . . . . . . . . 217 136

. . . 22 . . . . . . . . . . . . . . . . . . .

. . .

. . .

. . .

. . .

23

24

24

24

. . . . . . . . . . . . . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . . .

T1

T1

T1

TP1,2

TP4,5

RC13

. . . . . . .

. . . . . . .

. . . . . . .

PLG13

. . . . . .

. . . . . .

. . . . .

. . . . . .

176 254

163 359

218 396

218 397

218 398

175 405

168 891

189 873

189 874

. .

. .

. .

. .

. .

. .

. .

. .

CONTACTOR, def prp 75A 3P 24VAC

SWITCH, reed

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, general precautionary wordless,intl (CE models only) . . . .

BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSFORMER, pwr main 230/460/575 . . . . . . . . . . . . . . . . . . . . .

TRANSFORMER, pwr main 380/400/440

TRANSFORMER, pwr main 380/520

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . .

. .

. .

THERMOSTAT, NC (Included w/T1)

THERMOSTAT, NC (Included w/T1)

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 27 . . . . . . . . . . . . . . . . . . .

. . . 28 . . . . . . . . . . . . . . . . . . . .

161 294

Fig 8-2

. .

. .

BRACKET, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 29 . . . . . . . SR1 . . . . . . 192 671 . .

RECTIFIER, si diode (Fig 8-3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 30 . . . . . . . . . . . . . . . . . . . 604 536 . . SCREW, .312-18 x 1.75 hexhd-pln gr 5 . . . . . . . . . . . . . . . . . . . . . . .

♦

Part of Option 195048 Ground Current Sensor.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

2

1

1

1

1

2

2

2

1

1

1

1

2

2

1

1

*Recommended Spare Parts.

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-278 Page 31

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 28)

. . . 1 . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . 2 . . . . . . .

PLG6

RC6

PLG7

RC7

PC1

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . 2 . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . .

PC1

PLG1

PLG3

. . . . . . . . . . . . . PLG4

. . . . . . . . . . . . . PLG5

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . . . . . . . . PLG16

. . . 3 . . . . . . . CR3

. . . . .

. . . . . .

. . . 4 . . . . . . .

. . . 5 . . . . . .

CR5

CB1,2

. . . . . .

. . . . . .

. . . 6 . . . . . . . RC9 . . . . . .

. . . 7 . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . .

RC8 . . . . . .

C3,6,13,14 . . .

. . . 8 . . . . . . . . . . . . . . . . . . .

. . . 9 . . . . . . . . . . . . . . . . . . .

. . . 10 . . . .

. . . 11

POS-CC,CV

. . . . . . C2,4,5

. . .

. . . . .

. . . 13 . . . . . . . NEG . . . . . .

158 719

052 964

006 393

093 995

604 176

203 778

143 976

097 749

204 143

161 303

039 047

128 750

039 046

159 863

168 847

168 845

152 249

168 846

207 032

207 033

158 720

169 240

148 439

152 249

.

Hardware is common and not available unless listed.

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR & SOCKETS

CONNECTOR & PINS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT CARD, control (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT CARD, control (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR & SOCKETS, (see Fig 8-3)

CONNECTOR & SOCKETS

CONNECTOR & SOCKETS

CONNECTOR & SOCKETS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

. .

. .

. .

. .

. .

. .

. .

. .

CONNECTOR & SOCKETS

RELAY, encl 24VDC DPDT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

. .

RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . .

RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . .

CONNECTOR/CAPACITOR, w/leads (consisting of) . . . . . . . . . . . .

. . . .

. . . .

RCPT w/SCKTS (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAPACITOR, cer disc .05 UF 500 VDC strip . . . . . . . . . . . . . . . .

PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPRING, cprsn .600 OD x .072 wire x 1.500 lg . . . . . . . . . . . . . . . .

TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAPACITOR, cer disc .1uf 500VDC . . . . . . . . . . . . . . . . . . . . . . . . . .

TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

1

1

1

1

1

2

3

1

3

1

1

1

1

4

1

2

1

1

1

1

1

5

6

7

8

2

1

3

9

10

11

36

10

11

35

4 36

37

24

25

11

36

34

23

24

25

26

22

21

14

13

20

19

28 27 18

33

29

32

31

30

ST-800 705-G

Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 30)

OM-278 Page 32

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 28) (Continued)

. . . 14 . . . . . . . . . . . . . . . . . . .

. . . 14 . . . . . . . . . . . . . . . . . . .

. . . 18 . . . . . . . . . . . . . . . . . . .

. . . 18 . . . . . . . . . . . . . . . . . . .

. . . 19 . . . . . . . . . . . . . . . . . . .

. . . 20 . . . . . . . . . . . . . . . . . . .

. . . 21 . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . 22 . . . . . . . . . . . . . . . . . . .

. . . 23 . . . . . . . .

. . . 24 . . . . . . .

S1

S3,4

. . . . . . .

. . . . . .

174 937

179 389

217 865

179 563

160 530

160 935

601 835

010 913

038 887

011 610

011 609

. . . 25 . . . . . .

. . . 26 . . . . . . .

R1, R2

PC2

. . . . .

. . . . . .

. . .

. . .

31

32

. . . . . . . PL2 . . . . . . .

. . . . . . . . . . . . . . . . . . .

198 087

213 249

. . . . . . . . . . . . PLG10

. . . . . . . . . . . .

. . . 27 . . . . . . .

PLG11

CR2

. . . . .

. . . . .

. . . . . .

. . . 28 . . . . . . . . . . . . . . . . . . .

153 501

148 439

116 592

192 174

. .

. .

. .

. .

. . . 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 30 . . . . . . . . S2

. . . . . . . . . . . . . PLG2

. . . . . . .

. . . . . .

159 039

185 626

159 522

159 036

. .

. .

. .

. .

. .

. .

. . .

. . .

. . .

33

34

35

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . SN1 . . . . . .

. . . 36 . . . . . . . . . . . . . . . . . . .

. . . 37 . . . . . . . . . . . . . . . . . . .

097 924

097 922

197 868

010 381

162 815

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

. .

PLATE, control lower (60Hz)

PLATE, control lower (50Hz)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, warning electric shock and reduced air . . . . . . . . . . . . . . . .

LABEL, electric shock/reduce air flow (CE models only)

COVER, stud output

. . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WASHER, flat .218 ID brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STUD, pri bd brs 10-32 x 1.375

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH, tgl SPDT 15A 125VAC

SWITCH, tgl SPDT 15A 125VAC

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

POTENTIOMETER, CP std slot 1/T 2W 1K ohm

CIRCUIT CARD, digital meter

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR & SOCKETS

CONNECTOR & SOCKETS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RELAY, encl 24VDC 3PDT

STAND-OFF

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . .

SWITCH, rocker SPDT 15A 125VAC

CONNECTOR, body 56 series

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED, yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LENS, LED clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KNOB, pointer

KNOB, pointer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SNUBBER, assy

Connector, rectifier

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

1

1

4

1

1

1

1

2

1

1

3

1

1

2

1

1

1

1

1

3

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-278 Page 33

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 8-3. Rectifier, Si Diode (Fig 8-1 Item 29)

. . . 1 . . . . C7.12

. . . .

. . . 2 . . . . . . . . . . . . . . .

048 420

191 989

. .

. .

CAPACITOR, cer disc .01uf 1000VDC

BAR, mtg rectifier

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .

. . .

3

4

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

188 691

188 839

. .

. .

CLAMP, thyristor rectifier 5.500

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEAT SINK, rectifier snowflake .800

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2

3

12

. . . 5 . . .

. . . . . . . . . .

SCR1-6 . . .

. . . 6 . . . . . . . . . . . . . . .

PLG1 . . . .

. . . . . . . . . . . TP3

. . . . . . . . . . . TP6

. . . . .

. . . . .

148 091

166 667

. .

. .

THYRISTOR, SCR 865A 300V hockey puck

CLAMP, spring thyristor rectifier 5.500

. . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 673

192 674

. .

. .

THERMOSTAT, rectifier

THERMOSTAT, rectifier

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

3

1

1

1

.

Hardware is common and not available unless listed.

2

3

1

5

4

6

ST-802 351

Figure 8-3. Rectifier, Si Diode

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-278 Page 34

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 8-4. Panel, Rear w/Components (Fig 8-1 Item 18)

. . .

. . .

. . .

. . .

1

2

3

4

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

173 283

180 165

. .

. .

CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLADE, fan 14 in 3wg 23deg .375 bore CCW . . . . . . . . . . . . . . . . . . . . . .

162 807

168 343

. .

. .

PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HINGE, door primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .

. . .

5

6

. . . . . . . . . . . . . . +162 818

. . . . . . . . . . . . . . . 217 138

. .

. .

DOOR, access primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, warning electric shock/input power . . . . . . . . . . . . . . . . . . . . . . . .

. . . 6 . . . . . . . . . . . . . . . 179 290 . . LABEL, warning electric shock input connection (CE models only) . . .

. . .

. . .

. . .

. . .

7

8

9

10

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . .

. . . . .

R3

FM

. . . . . .

. . . . .

. . . 11 . . . . . . . . . . . . . . .

602 177

124 274

. .

. .

SCREW, set .250-20 x .250knrlpt sch stl

BRACKET, mtg fan motor

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

097 459

208 402

. .

. .

RESISTOR, WW fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTOR, 1/12HP 230V 1550RPM 50/60Hz .83A

. . . . . . . . . . . . . . . . . . .

010 467 . . CONNECTOR, clamp cable 1.250

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2

1

1

1

1

1

1

1

2

1

1

.

Hardware is common and not available unless listed.

3

4

5

6

2

1

7

11

8

10 9

ST-800 707-B

Figure 8-4. Panel, Rear w/Components

+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-278 Page 35

Notes

Notes

Notes

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.

Effective January 1, 2004

(Equipment with a serial number preface of “LE” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.

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

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2.

3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig

* Maxstar 150

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3.

1 Year — Parts and Labor Unless Specified

* 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 and Coolers

* Water Coolant Systems (Non-Integrated)

* Flowgauge and Flowmeter Regulators (No Labor)

* HF Units

* Grids

* Maxstar 85, 140

* Spot Welders

* Load Banks

* Arc Stud Power Sources & Arc Stud Guns

* Racks

* 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 & SAF 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. (Exception: brushes, slip rings, and relays are covered on Bobcat,

Trailblazer, and Legend models.)

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 6/04

Owner’s Record

Please complete and retain with your personal records.

Serial/Style Number Model Name

Purchase Date

Distributor

Address

City

State

(Date which equipment was delivered to original customer.)

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:

Contact the Delivering Carrier to:

PRINTED IN USA

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information and Parts)

Circuit Diagrams

Welding Process Handbooks

File a claim for loss or damage during shipment.

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s

Transportation Department.



2004 Miller Electric Mfg. Co. 1/04

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066 www.MillerWelds.com