Maxstar 300 DX - Miller Welding

OM-2222
189533C
August 1999
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
230/460 Volt Models W/AutolinkR
400 Volts Models
Arc Welding Power Source
R
Maxstar 300 DX
And Non-CE Models
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding figure out what the problem is. The parts list
equipment manufacturer in will then help you to decide which exact part
the U.S.A. to be registered
you may need to fix the problem. Warranty and
to the ISO 9001 Quality
service information for your particular model
System Standard.
are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
Working as hard as you
do − every power source
from Miller is backed by
the most hassle-free warranty in the business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
TABLE OF CONTENTS
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
OM-2222C
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturer’s Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. 115 Volts AC Duplex Receptacle, Circuit breaker (Optional) And Power Switch . . . . . . . . . .
3-6. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Remote Program Select Inputs (Optional For Non CE Models) . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Description Of Controls (Use With Sections A And B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Remote Trigger (Normal) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Remote Trigger (2T) Hold Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. 4T (Specific Trigger Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Reconfiguring 4T For Mini Logic Control, Spot, Contactor On, Or Lift-Arc . . . . . . . . . . . . . . .
4-7. Mini Logic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Spot Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Contactor On Lift-Arc Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Lift-ArcE And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Programmable HF Start Amperage And Time Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Arc Timer/Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Lock Out Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − SELECTING AND PREPARING
TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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Declaration of Conformity For
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit.)
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
Maxstar R 300 DX
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Capability Directives: 89/336, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(December 1996 − Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
European Contact:
Telephone:
Fax:
dec_con1 10/95
Mr. Luigi Vacchini, Managing Director
MILLER Europe S.P.A.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
1-1. Symbol Usage
Means Warning! Watch Out! There are possible
hazards with this procedure! The possible hazards are
shown in the adjoining symbols.
Y Marks a special safety message.
.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-4. Read and
follow all Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable − do not use work clamp or work cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Keep all panels and covers securely in place.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Use AC output ONLY if required for the welding process.
D Keep your head out of the fumes. Do not breathe the fumes.
D If AC output is required, use remote output control if present on
unit.
D If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
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 If ventilation is poor, use an approved air-supplied respirator.
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.
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-2222 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.
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.
D Wear protective clothing made from durable, flame-resistant
material (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire. Check and be sure the
area is safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D 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.
D Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
CYLINDERS can explode if damaged.
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).
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 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 Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Never drape a welding torch over a gas cylinder.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D Never weld on a pressurized cylinder − explosion will result.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-2222 Page 2
D Never allow a welding electrode to touch any cylinder.
D Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
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.
D Do not overload building wiring − be sure power supply system
is properly sized, rated, and protected to handle this unit.
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.
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.
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.
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.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D 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.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-2222 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-2222 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 − CONSIGNES DE SECURITE
− LIRE AVANT UTILISATION
som _nd_fre 5/97
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Y Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité
énumérées à la section 1-4. Veuillez lire et respecter toutes ces
normes de sécurité.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique, et décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.
D Ne jamais toucher les pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.
D Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
D Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
D Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes
de sécurité).
D Installer et mettre à la terre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé − remplacer le cordon immédiatement s’il est
endommagé − un câble dénudé peut provoquer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de
retour.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D
D
D
D
D
D
D Eloigner votre tête des fumées. Ne pas respirer
les fumées.
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les instructions du fabricant concernant les métaux, les consommables,
les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
rayons de l’arc peuvent réagir en présence de vapeurs et former
des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.
OM-2222 Page 5
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées
pendant le soudage.
D Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
D Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être
projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Se protéger et d’autres personnes de la projection d’étincelles et de
métal chaud.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Déplacer toutes les substances inflammables à une distance de 10,7
m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.
D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par
des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent
de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-2222 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
D Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.
D Ne pas toucher des parties chaudes à mains
nues
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D 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.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
D Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces infllammables.
D Rester à l’écart des organes mobiles comme le
ventilateur.
D Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables
D Ne pas surcharger l’installation électrique − s”assurer que l’alimentation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un engin d’une capacité appropriée pour
soulever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
D
D
D Prévoir une période de refroidissement, respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
D
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
D Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant
le fil de soudage.
D Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.
D
D
D
D L’énergie
électromagnétique
risque
de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-2222 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a
encore un certain souci à propos de tels champs. Cependant, après
avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du
National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux
champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine”. Toutefois, des études sont
toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il
vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-2222 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible
de vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il
est alors recommandé de respecter les consignes ci−dessus.
SECTION 2 − DEFINITIONS (CE Models)
2-1. Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1.3
2
1
1.1
1.2
1.3
2.1
2.2
2.3
2
2.1
2.2
2.3
3
3.1
3
3.1
3.2
3.2
3.3
3.3
4
4
4.1
+
5
+
+
4.1
6
+
5
6
S-179 310
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet
or damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working
on the machine or welding.
Do not remove or paint over
(cover) the label.
1/96
OM-2222 Page 9
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
2
1
2
4
3
5
V
V
> 60 s
V
3
4
5
6
S-185 836
7
6
9
8
7
8
9
1
1
2
3
∠ = <60 °
4
∠
5
Electric shock from wiring
can kill.
Disconnect input plug or
power before working on
machine.
Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
Always wait 60 seconds after
power is turned off before
working on unit, OR
Check input capacitor
voltage, and be sure it is near
0 before touching any parts.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
Always wear long sleeves
and button your collar when
servicing unit.
After taking proper
precautions as shown,
connect power to unit.
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
Use a proper cart to move
unit.
Do not use one handle to lift
or support unit.
S-179 309-A
2
3
4
5
1/96
OM-2222 Page 10
2-2. Manufacturer’s Rating Label For CE Products
.
For label location
see Section 3-4.
ST-188 153-A
OM-2222 Page 11
2-3. Symbols And Definitions
A
Amperes
Panel−Local
V
Volts
Input
Output
Circuit Breaker
Remote
Protective Earth
(Ground)
Postflow Timer
Preflow Timer
On
Off
Positive
Alternating
Current
Gas Input
Gas Output
Duty Cycle
Direct Current
Line Connection
X
U1
U0
Primary Voltage
IP
Degree Of
Protection
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
3 Phase Static Frequency
Converter-Transformer-Rectifier
I1max
Rated Maximum
Supply Current
Touch Start
(GTAW)
S
Seconds
Negative
I2
Rated Welding
Current
U2
Conventional Load
Voltage
I1eff
Maximum Effective
Supply Current
Rated No Load
Voltage (Average)
Pulse Background
Amperage
Initial Amperage
Increase/Decrease
Of Quantity
Normal Trigger
Operation (GTAW)
Two-Step Trigger
Operation (GTAW)
Four-Step Trigger
Operation (GTAW)
Percent
Hertz
Recall From
Memory
Arc Force (DIG)
Impulse Starting
(GTAW)
Final Slope
Final Amperage
Pulse Percent
On Time
Initial Slope
Contactor Control
(Stick)
Pulser On-Off
TIG Weld Amps
And Peak Amps
While Pulsing
Pulse Frequency
Hz
OM-2222 Page 12
SECTION 3 − INSTALLATION
3-1. Specifications
A. For Multivoltage Units
Input
Power
Rated Output at
60% Duty Cycle
Welding
Amperage
Range
Max.
Open-Circuit
Voltage
Amperes Input At
Rated Output, 60Hz
230
460
KVA
KW
Dimensions
H: 17 in (432 mm)
ThreePhase
250 A @ 30 VDC,
60% Duty Cycle
5 − 300
95
25.4
0.23*
16.2
0.14*
12.8
0.11*
8.8
0.06*
SinglePhase
200 A @ 28 VDC,
60% Duty Cycle
5 − 300
95
40.2
0.32*
-−
9.3
0.11*
6.8
0.06*
D: 24 in (610 mm)
KVA
KW
Dimensions
Net
Weight
W: 12-1/2 in (318 mm)
82 lb
(37 kg)
100 lb
(45 kg)
w/aux.
power
*While idling
B. For Single Voltage Units
Rated Output at
60% Duty Cycle
Welding
Amperage
Range
Max.
Open-Circuit
Voltage
Amperes Input
At Rated Output,
50Hz - Three-Phase 400 V
Net
Weight
H: 17 in (432 mm)
250 A @ 30 VDC,
60% Duty Cycle
5 − 300
95
16.9
0.15*
11.7
0.10*
8.6
0.03*
W: 12-1/2 in (318 mm)
D: 24 in (610 mm)
82 lb
(37 kg)
100 lb
(45 kg)
w/aux.
power
*While idling
3-2. Volt-Ampere Curves
Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
welding power source. Curves of
other settings fall between curves
shown.
ST-190 014
OM-2222 Page 13
3-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 5-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
Y
Exceeding duty cycle can
damage unit and void
warranty.
250 A @ 60% Duty Cycle For Three-Phase Models
200 A @ 60% Duty Cycle For Single-Phase Models
6 Minutes Welding
4 Minutes Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
ST-186 863 / ST-190 012
OM-2222 Page 14
3-4. Selecting A Location
1
Lifting Handles
Use handles to lift unit.
Dimensions And Weight
82 lb (37 kg) − 100 lb (45 kg) w/aux power
2
24 in
(610 mm)
Hand Cart
Use cart or similar device to move
unit.
3
Rating Label (Non CE
Models)
Use rating label to determine input
power needs.
17 in
(432 mm)
4
5
Plate Label (CE Models)
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.
12-1/2 in
(318 mm)
Movement
Y
1
Do not move or operate unit
where it could tip.
1
2
Location And Airflow
5
3
18 in
(460 mm)
4
18 in
(460 mm)
ST-802 137
OM-2222 Page 15
3-5. 115 Volts AC Duplex Receptacle, Circuit breaker (Optional) And Power Switch
1
1
2
2
3
AC Duplex Receptacle
115 V 10 A for 230/460 volt models.
115 V 7 A for 400 volt models.
Circuit Breaker CB1
CB1 protects duplex receptacle
from overload.
Press button to reset breaker.
3
Power On/Off Switch
Ref. ST-801 866
3-6. Weld Output Terminals And Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
Weld Output
Terminals
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
10 − 100% Duty Cycle
−
+
Output Receptacles
*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 local distributor for the mm2 equivalent weld cable size.
**Select weld cable size for pulsing application at peak amperage value.
NOTE: For proper installation of gas hose, the use of a quick-connect torch (such as a Weldcraft QWP-17 or QWP-20) is recommended
..
S-0007-D
OM-2222 Page 16
3-7. Remote 14 Receptacle Information
Socket*
A
B
Socket Information
J
K
I
A
Contactor control 24 volts dc.
B
Contact closure to A completes 24 volts dc
contactor control circuit and enables output.
C
Output to remote control; 0 to +10 volts dc output
to remote control.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
A/V
F
Current feedback; +1 volt dc per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt dc per 10 volts output.
GND
K
Chassis common.
24 VOLTS DC
H
C L N
M
D
G
E F
OUTPUT
CONTACTOR
REMOTE
OUTPUT
CONTROL
ST-802 137
*The remaining sockets are not used.
3-8. Remote Program Select Inputs (Optional For Non CE Models)
10-Pin Receptacle RC2
Pin Designations 0 = No Connection /
1 = Connected To Ground (Pin G)
X= Do Not Care
Function
A
B
C
D
J
H
I
C
F
E
D
No Remote Control
0
0
X
X
Stick EP Of Current Program
1
0
X
X
Program 1 Stick EP
1
1
0
0
Program 2 Stick EP
1
1
0
1
Program 3 Stick EP
1
1
1
0
Program 4 Stick EP
1
1
1
1
Program 1 TIG EN
0
1
0
0
Program 2 TIG EN
0
1
0
1
Program 3 TIG EN
0
1
1
0
Program 4 TIG EN
0
1
1
1
G
F
E
ST-802 137
*The remaining sockets are not used.
Socket A
Contactor control, 24 volts dc
Socket B
Contact closure to A, completes 24 volts dc
contactor control circuit and enables output
Socket G
Chassis Ground
Socket I
Normally open valid arc relay
Socket J
Circuit common for valid arc relay
To use the Remote Process Select function for a given program, select the TIG process on the front panel while the desired program is selected.
OM-2222 Page 17
3-9. Gas Connections
1
Gas Fitting
Fittings have 5/8-18 right-hand
threads.
2
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
3
4
4
3
2
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cfh (cubic
feet per hour).
Connect customer supplied gas
hose between regulator/flowmeter
and gas fitting on rear of unit.
1
Tools Needed:
5/8, 1-1/8 in
ST-801 866
3-10. Electrical Service Guide
A. For Multivoltage Units
NOTE
Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.
Three-Phase
Single-Phase
Input Voltage
230
460
230
Input Amperes At Rated Output
25
15.8
40.2
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
50
25
60
Min Input Conductor Size In AWG/Kcmil
10
14
8
123 (38)
197 (60)
139 (42)
10
14
10
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).
S-0092J
B. For Single Voltage Units
Input Voltage
400
Input Amperes At Rated Output
16.9
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
25
Min Input Conductor Size In AWG/Kcmil
14
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).
OM-2222 Page 18
153 (47)
14
S-0092J
3-11. Connecting Input Power
Check input voltage available at
site.
1
2
Input And Grounding
Conductors
Line Disconnect Device
See Section 3-10.
For non-CE three-phase
operation:
3
1
Y
Always connect green wire
to supply grounding terminal, never to a line terminal.
Connect black, white, and red
wires (L1, L2, L3) to line terminals.
For
CE
operation:
Y
2
2
three-phase
Always connect green/yellow wire to supply grounding terminal, never to a line
terminal.
Connect black, brown, and blue
wires (L1, L2, L3) to line terminals.
For single-phase operation:
L1
L2
L1
L3
L2
Green
Green Or
Green/Yellow
Y
Always connect green wire
to supply grounding terminal, never to a line terminal.
3
Black And White Input
Conductor
Red Input Conductor
Insulation Sleeving
Electrical Tape
4
5
6
1
1
Always connect grounding
conductor first.
Y
Insulate and isolate red conductor
as shown.
= GND/PE
1
3
4
Green
1
6
5
input_2 3/96 - ST-802 138
OM-2222 Page 19
SECTION 4 − OPERATION
4-1. Controls
A.
For 230/460 Volts And Non CE Units (Use With Section 4-2)
3
2
1
12
20
4
21
5
6
22
23
7
8
24
11
10
25
9
16
17
18
TIG Function Keys
19
13
14
15
Memory
Function
Keys
Stick Function Keys
26
Rear Panel
ST-188 476-B / Ref. ST-801 866
OM-2222 Page 20
B. For CE Units (Use With Section 4-2)
3
2
1
12
20
4
21
5
6
22
23
7
8
24
11
10
25
9
16
17
18
TIG Function Keys
19
13
14
15
Memory
Function
Keys
Stick Function Keys
26
Rear Panel
ST-186 715-A / Ref. ST-801 866
OM-2222 Page 21
4-2. Description Of Controls (Use With Sections A And B)
.
1
For all front panel switch pad controls:
press switch pad to turn on light and
enable function.
to select length of time, 0−25 seconds, that
it takes to slope the amperage up/down
from start amperage to weld amperage.
Encoder Control
12 TIG Weld Amps And Peak Amps
While Pulsing Control
Use encoder control in conjunction with
applicable front panel function switch pads
to change values for that function.
2
Ammeter
Displays amperage and preset parameters for pulse frequency, % of background
amperage, % of dig, and % of peak time.
3
Voltmeter
Displays arc voltage and the following preset times (preflow, initial slope, final slope,
and postflow) in seconds, for applicable
function controls.
13 Final Slope Time Control
18 Pulse Width Control
Press switch pad and turn Encoder Control
to select length of time, 0−25 seconds, that
it takes to slope the amperage up/down
from weld amperage to final amperage.
Press switch pad and turn Encoder Control
to set percentage of time, 5−95%, amperage is at peak for each pulse.
Application:
To reconfigure 4T control for use as Spot,
Contactor On Lift-Arc , and Mini Logic
control, see Section 4-6.
Note: This applies if the operator is using
an on/off only type control to start and stop
the welding process.
5
14 Final Amperage Control
Remote Trigger (2T) Hold Mode
See Section 4-4.
6
Remote Trigger (Normal) Mode
See Section 4-3.
7
Lift-Arc Start Mode
Press switch pad and turn Encoder Control
to select 5−300 amps of final amperage.
Final amperage is the amperage to which
the weld amperage has sloped up/down
to.
See Section 4-10.
15 Postflow Time Control
8
Press switch pad and turn Encoder Control
to set time, 0−50 seconds, gas flows after
welding stops.
HF Start Mode
See Section 4-10.
9
Preflow Time Control
Press switch pad and turn Encoder Control
to set time, 0−15 seconds, gas flows before welding electrode is energized. Preflow control is disabled if Lift-Arc Start
mode is selected.
Application:
Preflow is used to purge the immediate
weld area of atmosphere. Preflow also
aids in consistent arc starting.
10 Initial Amperage Control
Press switch pad and turn encoder control
to select a starting amperage, 5−300
amps, that is different from the weld amperage.
Application:
Initial Amperage can be used while GTAW
welding to assist in preheating a cold material prior to depositing filler material.
11 Initial Slope Time Control
Press switch pad and turn Encoder Control
OM-2222 Page 22
17 Pulse Frequency Control
Press switch pad and turn Encoder Control
to set pulse frequency, .1−500 pps (pulses
per second).
See Section 4-5.
4 T (Specific Trigger Method)
Pulsing can also be used for filler material
addition technique training.
Press switch pad and turn Encoder Control
to select 5−300 amps for TIG welding, or
peak amps while pulsing.
Final Slope Time should be used while
GTAW welding materials that are crack
sensitive, and/or the operator wants to
eliminate the crater at the end of the weld.
4
ting, and heat input. Controls can be adjusted while welding.
Application:
Postflow is required to cool tungsten and
weld, and to prevent contamination of
tungsten and weld. Increase postflow time
if tungsten or welds are dark in
appearance.
16 Pulser On/Off Control
Press switch pad to turn on light and enable pulser function.
Application:
Pulsing refers to the alternating raising and
lowering of the weld output at a specific
rate. The raised portions of the weld output
are controlled in width, height, and frequency, forming pulses of weld output.
These pulses and the lower amperage level between them (called the background
amperage) alternately heat and cool the
molten weld puddle. The combined effect
gives the operator better control of penetration, bead width, crowning, undercut-
19 Background Amperage Control
Press switch pad and turn Encoder Control
to set background amperage as a percentage, 5−95%, of peak amperage.
20 TIG Process Select Mode
Press switch pad to select TIG Process.
21 1−4 Program Storage
Each program switch pad, 1−4, is capable
of storing two welding parameters programs, four for TIG, or four for Stick, depending on whether TIG function or Stick
function switches are enabled. A total of
eight welding parameter programs can be
recalled. The weld parameters and selected memory positions are updated anytime a parameter is changed. To recall a
program, press the desired process switch
pad, and program pad 1−4.
22 Stick Process Select Mode
Press switch pad to select Stick process.
23 Output Contactor Control (Stick)
Press switch pad to turn on light and enable output.
24 Stick Amperage Control
Press switch pad and adjust Encoder Control to select 5−300 amps for Stick welding.
25 DIG Control
Press switch pad and adjust Encoder Control to set DIG (0−100%).
When set lower, short-circuit amperage at
low arc voltage is the same as normal
welding amperage.
When set higher, short-circuit amperage is
increased at low arc voltage to help with
arc starting and making overhead or vertical welds, as well as to reduce sticking
while welding.
26 Power On/Off Switch
Located on rear panel.
4-3.
Remote Trigger (Normal) Mode
1
1
Remote Switch Pad
Press switch pad to activate function.
Torch trigger operation is as shown.
NOTE: When a foot or finger remote
control is connected to the welding
power source, initial amps, initial
slope, final slope, and final amps
are not functional.
NOTE: Initial weld amperage and final amperage is controlled by the
remote device, not by the welding
power source.
NOTE: If On/Off only type trigger is
used, it must be a maintained
switch. All functions become active.
Application: Use Remote Trigger
when the operator desires to use a
foot pedal or finger amperage control.
Current (A)
Torch Trigger Operation
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Foot Or Finger
Remote Control
Release For
Maintained Switch
Release Foot Or
Finger Remote
Control
OM-2222 Page 23
4-4.
Remote Trigger (2T) Hold Mode
1
1
Remote Trigger Hold Switch
Pad
Press switch pad to activate function.
Torch trigger operation is as shown.
NOTE: When a foot or finger remote
control is connected to the welding
power source, only trigger input is
functional.
NOTE: Amperage is controlled by
the welding power source.
Application: Use Remote Trigger
Hold (2T) when long extended
welds are made. Remote Trigger
Hold (2T) can help to reduce operator fatigue.
Current (A)
Torch Trigger Operation
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release Trigger
In Less Than 3/4 Sec.
Push & Release Trigger
In Less Than 3/4 Sec.
NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Normal) mode (see Section 4-3).
If arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 5-3).
OM-2222 Page 24
4-5.
4T (Specific Trigger Method)
1
4T Switch Pad
Press switch pad to activate function.
1
Torch trigger operation is as shown.
While in 4T mode, there is a feature
available during the main weld sequence that allows the operator to
toggle between weld current and
final current without breaking the
arc.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.
Application:
Use 4T trigger method when the
functions of a remote current control
are desired, but only a remote on/off
control is available.
Current (A)
Torch Trigger Operation
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Trigger
Release
Trigger
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger
Release
Trigger
OM-2222 Page 25
4-6. Reconfiguring 4T For Mini Logic Control, Spot, Contactor On, Or Lift-Arc
1
2
2
To reconfigure 4T, push and hold 4T
switch pad and turn On power
switch. Hold switch pad for approximately 7 seconds (or until software
version number _ _ _ _ _ _-_clears,
and meters display [-−−] [H−4]).
3
Rear Panel
4T Switch Pad
Power Switch
3
Encoder Control
Use Encoder to change functions.
Active function will be displayed on
amperage (right) meter.
1
−−−
4
H−4
Meter Displays
Meter displays for the different functions will be as shown.
Press torch trigger or turn power Off
to save setting. Lift-Arc requires a
power down.
Proceed to Section 4-7 for Mini
Logic operation.
Proceed to Section 4-8 for Spot
Control Operation.
Proceed to Section 4-9 for Contactor On Lift-Arc Operation.
−−−
H−4
−−−
H4L
=
4T (See Section 4-5)
=
Mini Logic (See Section 4-7)
4
OM-2222 Page 26
−−−
SPO
−−−
O−1
=
=
Spot (See Section 4-8)
Lift-Arc
(See Section 4-9)
4-7. Mini Logic Operation
1
1
Mini Logic Meter Display
Select Mini Logic according to Section 4-6.
Torch trigger operation is as
shown.
−−−
H4L
=
Mini Logic
During Mini Logic welding operation, the weld current can be manually changed from the initial amps
level to the main weld amps level
by pressing and releasing the torch
trigger in less than 3/4 seconds.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.
Application: This ability to change
current levels without either initial
slope or final slope, gives the operator the opportunity to adjust filler
metal without breaking the arc.
Torch Trigger Operation
Weld Amps
Final Slope
Rate
Initial Slope
Final Slope
Start Amps
Initial Amps
Final Slope
Rate
Preflow
Push & Hold
Trigger
Push & Hold
Trigger For More
Than 3/4 Sec.
Release Trigger
Postflow
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger For More
Than 3/4 Sec.
Push & Hold
Trigger For More
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
OM-2222 Page 27
4-8. Spot Control Operation
1
1
2
3
−−−
Spot Function Meter Display
Select Spot function according to
Section 4-6.
3
SPO
=
Spot
TIG Weld Amps And Peak
Amps While Pulsing Switch
Pad
Encoder Control
Set spot parameters as follows:
Press switch pad once (amps LED
lights) and turn Encoder to set spot
amperage. Press switch pad again
(seconds LED lights) and turn Encoder to set spot time (.1−25 seconds).
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.
Torch trigger operation is as
shown.
2
Application: To provide a timed
weld. Used for tacking, and thin
sheet joining.
Current (A)
Torch Trigger Operation
Timed Spot Weld Amps
Preflow
Postflow
Push & Hold
Trigger
Release
Trigger
NOTE: If arc is broken and trigger is depressed, or trigger is still depressed after postflow time is complete, HLP-10 will
be displayed (see Section 5-3).
OM-2222 Page 28
4-9. Contactor On Lift-Arc Operation
1
1
Contactor On Lift-Arc Meter
Display
Select Contactor On Lift-Arc function according to Section 4-6.
Proceed to Section 4-10 Lift-Arc
start procedures.
−−−
O−1
=
Lift-Arc
Application: Lift-Arc is used for
the DCEN GTAW process when
the HF start method is not permitted, or to replace the scratch
start method. Also, allows for the
use of Lift-Arc without a remote on/
off switch.
NOTE: Preflow is a manual function and begins when the tungsten contacts the weldment. The length of time is determined by the
operator. Postflow is a timed function, and begins when the arc is manually broken.
4-10. Lift-Arc And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
1
“Touch”
1−2
Seconds
2
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point, enable
output with torch trigger, foot control, or hand control. Hold
electrode to workpiece for 1-2
seconds, and slowly lift electrode.
An arc will form when electrode is
lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between electrode and workpiece.
The solid-state output contactor
does not energize until after electrode is touching workpiece. This
allows electrode to touch workpiece
without
overheating,
sticking, or getting contaminated.
Application:
Do NOT Strike Like A Match!
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to replace the scratch method.
HF Start
When HF Start button light is On,
start arc as follows:
High frequency turns on to help
start arc when output is enabled.
High frequency turns off when arc
is started, and turns on whenever
arc is broken to help restart arc.
OM-2222 Page 29
4-11. Programmable HF Start Amperage And Time Modes
A.
Accessing Programmable HF Start Amperage And Time Modes
NOTE: Before accessing programmable HF start amperage and time
modes, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while programmable HF start and
time modes are active.
1
2
Lift-Arc And HF Start Mode
Switch Pads
Power Switch
To display the programmable HF
start amperage and time screens,
push and hold Lift-Arc and HF Start
switch pads and turn On power
switch. Hold switch pads for
approximately 7 seconds (or until
software version number _ _ _ _ _
_-_clears meters).
1
2
Proceed to Section B and/or C.
Rear Panel
B.
Setting Programmable HF Start Amperage
3
−5−
50
2
1
NOTE: Before accessing programmable
HF start amperage mode, be sure that all
procedures and parameters are established. Parameter adjustment is limited
while programmable HF start amperage
mode is active.
Welding cycle can be executed while in
programmable start mode, but program
parameters cannot be adjusted while in
this mode.
1 Initial Amps Switch Pad
OM-2222 Page 30
2 Memory Program Switch Pads (1−4)
3 Encoder Control
To adjust HF start amperage proceed as
follows:
Press desired memory switch pad (1−4) to
activate desired memory program and
turn on LED.
Press Initial Amps switch pad. Switch pad
LED turns on, meter A LED turns on, and
[−5− ] [50 ] is displayed on meters.
The “50 ” displayed on the amps meter is
DC start amps (it is also the factory default
setting), and can be adjusted from 1 to 200
amps by turning the Encoder control.
To change start time, proceed to Section
C. To save changes to HF start amperage
without changing start time, select a different memory program number, or turn power Off.
C. Setting Programmable Start Time
3
−5−
1
2
1
NOTE: Before accessing programmable
start time mode, be sure that all procedures and parameters are established.
Parameter adjustment is limited while programmable start time mode is active.
Welding cycle can be executed while in
programmable start mode, but program
parameters cannot be adjusted while in
this mode.
1
Initial Slope Switch Pad
2
Memory Program Switch Pads (1−4)
3
Encoder Control
To adjust start time proceed as follows:
If you are adjusting start time without having adjusted start amperage in Section B,
press desired memory switch pads (1−4)
to activate desired memory program and
turn on LED.
Press Initial Slope switch pad. Switch pad
LED turns on, meter S LED turns on, and
[−5− ] [1 ] is displayed on meters.
The [1 ] displayed on the amps meter is DC
start time (it is also the factory default setting), and can be adjusted from 1 to 200
milliseconds by turning the Encoder
control.
To save changes, select a different
memory program number, or turn power
Off.
OM-2222 Page 31
4-12. Arc Timer/Counter Display
1
2
To display the arc timer/counter,
push and hold Initial and Final
Slope control switch pads, and turn
On Power switch. Hold switch
pads for approximately 7 seconds
(or until software version number
_ _ _ _ _ _-_clears meters).
1
1
3
2
Arc Counter
OM-2222 Page 32
123
456
999
999
Arc Timer Display
Upon power up as described
above, the meter S and Memory 1
LEDs will turn on, and arc time will
be displayed for 5 seconds as [000
000 ] to [999 999 ]. The first four
numbers indicate hours, and the
last two numbers indicate minutes.
Arc time shown in example is read
as 1,234 hours and 56 minutes.
Maximum arc time is 9,999 hours
and 59 minutes.
4
Rear Panel
Arc Timer
Initial And Final Slope Control
Switch Pads
Power Switch
Arc Counter
After 5 seconds, the meter A and
Memory 2 LEDs turn on, and the
arc counter will be displayed for the
next 5 seconds as [000 000 ] to [999
999 ]. The maximum arc cycle
count is 999 999.
3
4
4-13. Lock Out Functions
A. Accessing Lock Out Capability
3
−−−
LL−0
−0
4
−−−
1
L−0
L−1
or 2,3,4
2
Rear Panel
See Section 4-1 for explanation of controls referred to in all of
Section 4-13.
There are four (1−4) different lock out levels. Each successive level
allows the operator more flexibility.
NOTE: Before activating lock out levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited
while lock out levels are active.
1 Memory Program Buttons 3 And 4
2 Power Switch
To access lock-out screens, press and hold memory program
switch pads 3 and 4, and turn On power switch. Hold switch pads
for approximately 7 seconds (or until software version number _ _
_ _ _ _-_clears meters).
3 Lock Out Off
If meter display is as shown, lockout feature is off.
4 Lock-Out On
If meter display is as shown, lockout feature is on.
To turn On the lock out feature, proceed as follows:
Enter a three digit code using the four Memory Program switch
pads. NOTE: If any switch pad other than a numbered Memory Pro-
gram switch pad is used, the lock out code is cancelled, and the lock
out condition will remain inactive.
Once three digits have been entered, the amperage screen display
will change from [L−0 ] to [L−−− ].
There are four lock out levels available. Enter any single digit (1−4),
using the Memory Program switch pads, to access a lock out level
(see Sections B and/or C).
Press torch trigger or turn Off power to complete lock out On
sequence.
To turn Off the lock out feature, proceed as follows:
To access lock-out screens, press and hold memory program
switch pads 3 and 4, and turn On power switch. Hold switch pads
for approximately 7 seconds (or until software version number
_ _ _ _ _ _-_clears meters).
Enter the same three digits that were used to turn on the lock out
feature. NOTE: If any switch pad other than a numbered Memory
Program key pad is used, the code is cancelled, and the lock out
condition will remain On.
Once the correct three digits have been entered, the amperage
screen display will change from [L-1 ] or 2,3,4 to [L−0 ].
Press torch trigger or turn Off power to complete lock out Off
sequence.
OM-2222 Page 33
B. Lock Out Levels
Level 1
Level 1
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
NOTE: Remote amperage control
is not available in level 1.
Trigger Selection
Allows for normal, 2T, or 4T trigger
mode to be selected if the TIG process was selected when lock out
feature was activated.
Or
Trigger Selection (TIG)
Contactor Control (Stick)
Stick Contactor Control
Allows for contactor control if the
Stick process was selected when
lock out feature was activated.
Level 2
Level 2
Select desired program
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
NOTE: Remote amperage control
is not available in level 2.
Includes all the functions of level 1
plus the following:
Program Selection
Program Selection 1−4
Gives operator the ability to select
desired program.
Process Selection − TIG or Stick
Gives operator the ability to select
the TIG or Stick process.
Lift-Arc Or HF Start Mode
Select TIG
or Stick
Process Selection
Or
Select Lift-Arc Or
HF Start mode
Lift-Arc Or HF Start Mode Selection
OM-2222 Page 34
Gives operator the ability to select
Lift-Arc or HF Start mode.
C. Lock Out Levels (Continued)
Level 3
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
Level 3
NOTE: Remote amperage control is
not available in level 3.
Includes all the functions of levels 1
and 2 plus the following:
+/− 10% adjustment of preset TIG
Weld Amps or Peak Amps While
Pulsing or Stick Weld Amps
Select TIG or Stick
Amperage control,
and use Encoder to
adjust amperage.
Select desired amperage control
(TIG or Stick, and use Encoder control to adjust amperage +/− 10% of
preset amperage value, up to the
limits of the machine.
Pulser ON/Off Control
Gives operator the ability to turn on/
off the Pulser control.
Level 4
+/− 10 % Amperage Adjust Control
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
Includes all the functions of levels 1,
2, and 3 plus the following:
Remote Amperage Control
Allows operator to use remote amperage control if desired. Remote
control operates from minimum to
maximum of preset amperage value. Connect remote control device
according to Section 3-7.
Turn Pulser control on/off
Pulser On/Off Control
Level 4
A
B
Remote Amperage Control
K
J
I
H
C L N
D M
G
E F
OM-2222 Page 35
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Y
Disconnect power before maintaining.
.
Maintain more often during severe conditions.
3 Months
Replace
unreadable
labels.
Clean and tighten
weld terminals.
Replace Damaged
Gas Hose
3 Months
Repair Or Replace
Cracked Cables
And Cords
6 Months
Y
Do not remove case when
blowing out inside of unit
(see Section 5-2) .
Blow out inside. During
heavy service clean
monthly.
5-2. Blowing Out Inside Of Unit
Y
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
ST-802 137
OM-2222 Page 36
5-3. Voltmeter/Ammeter Help Displays
V
A
0
V
A
HE.L
P−6
V
A
HE.L
P−7
V
A
HE.L
P−8
6
HE.L
P−0
V
A
1
7
HE.L
P−1
V
A
2
8
HE.L
P−2
V
A
V
A
HE.L
P−9
V
A
HE.L
P10
9
3
HE.L
P−3
V
A
4
10
HE.L
P−4
V
A
HE.L
P−5
5
.
0
All directions are in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
fan to cool it (see Section 3-3). Operation
will continue when the unit has cooled.
Help 0 Display
Indicates an open in the thermal protection
circuitry located on the right side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
Indicates a short in the thermal protection
circuitry located on the left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
1
Help 1 Display
Indicates a malfunction in the primary power circuit. Contact a Factory Authorized
Service Agent if this display is shown.
2
Help 2 Display
Indicates an open in the thermal protection
circuitry located on the left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
3
Help 3 Display
Indicates the left side of the unit has overheated. The unit has shut down to allow the
4
5
Help 4 Display
Help 5 Display
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 3-3). Operation
will continue when the unit has cooled.
6
Help 6 Display
Indicates that the input voltage is too low
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (±10%). Have
an electrician check the input voltage if this
display is shown.
7
Help 7 Display
Indicates that the input voltage is too high
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (±10%). Have
an electrician check the input voltage if this
display is shown.
8
Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. Contact a Factory
Authorized Service Agent if this display is
shown.
9
Help 9 Display
Indicates a short in the thermal protection
circuitry located on the right side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
10 Help 10 Display
Indicates torch trigger is depressed. Release trigger to continue.
OM-2222 Page 37
5-4. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-11).
Check for proper input power connections (see Section 3-11).
No weld output; meter display On.
If using remote control, be sure correct process is enabled to provide output control at Remote 14
receptacle (see Section 3-7 as applicable).
Input voltage outside acceptable range of variation (see Section 3-10).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-3).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 3-6).
Clean and tighten all weld connections (see Section 3-6).
No 115 volts ac output at duplex
receptacle.
Reset circuit breaker CB1 (see Section 3-5).
Fan not operating.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wandering arc
Use proper size tungsten (see Section 8).
Use properly prepared tungsten (see Section 8).
Reduce gas flow rate (see Section 3-9).
Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after conclusion of
Increase postflow time (see Section 4-1).
weld.
Check and tighten all gas fittings (see Section 3-9).
Water in torch. Refer to torch manual.
OM-2222 Page 38
Notes
OM-2222 Page 39
SECTION 6 − ELECTRICAL DIAGRAMS
Figure 6-1. Circuit Diagram For 230/460 Volt Models
OM-2222 Page 40
SC-189 463-B
OM-2222 Page 41
Figure 6-2. Circuit Diagram For 400 Volt CE Models
OM-2222 Page 42
SC-191 700
OM-2222 Page 43
Figure 6-3. Circuit Diagram For 400 Volt Non CE Models
OM-2222 Page 44
SD-190 989
OM-2222 Page 45
SECTION 7 − HIGH FREQUENCY
7-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG
high_freq 12/96 − S-0693
7-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
5
6
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
OM-2222 Page 46
7-3. Correct Installation
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
9
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
8
11 Overhead Door Track
Grounding Rod
Consult the National Electrical Code for
specifications.
Ground the track.
OM-2222 Page 47
SECTION 8 − SELECTING AND PREPARING
TUNGSTEN ELECTRODE
gtaw 7/97
NOTE
For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process. Wear clean gloves to prevent
contamination of tungsten electrode.
8-1. Selecting Tungsten Electrode
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC − Argon − Electrode Negative/Straight
Polarity
DC − Argon − Electrode Positive/Reverse
Polarity
.010”
Up to 25
*
.020”
15-40
*
2% Thorium Alloyed Tungsten (Red
Band)
.040”
25-85
*
1/16”
50-160
10-20
3/32”
135-235
15-30
1/8”
250-400
25-40
5/32”
400-500
40-55
3/16”
500-750
55-80
1/4”
750-1000
80-125
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour) − 7 to 16.5 lpm (liters per minute).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
8-2. Safety Information About Tungsten
Y
Grinding the tungsten electrode produces dust and flying sparks which can cause
injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear
an approved respirator.
Read MSDS for safety information. Consider using
tungsten containing ceria,
lanthana, or yttria instead of
thoria. Grinding dust from
thoriated electrodes contains low-level radioactive
material. Properly dispose
of grinder dust in an environmentally safe way. Wear
proper face, hand, and body
protection.
Keep
flammables away.
1
Tungsten Electrode With
Balled End
Pointed Tungsten Electrode
1
2
2
Ref. S-0161
OM-2222 Page 48
8-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding
1
1
2
2
Tungsten Electrode
Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before welding. Do not use wheel for other jobs
or tungsten can become contaminated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1
2
3
1
2
Stable Arc
Flat
Diameter of this flat determines
amperage capacity.
3
4
Grinding Wheel
Straight Ground
1
2
3
4
Arc Wander
Point
Grinding Wheel
Radial Ground
4
Ideal Tungsten Preparation − Stable Arc
1
2
3
4
Wrong Tungsten Preparation − Wandering Arc
Ref. S-0161 / Ref. S-0162
OM-2222 Page 49
SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW)
9-1. Positioning The Torch
Y
Grinding the tungsten electrode produces dust and flying sparks which can cause
injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear
an approved respirator.
Read MSDS for safety information. Consider using cerium or lanthanum based
tungsten instead of thoriated. Thorium dust contains low-level radioactive
material. Properly dispose
of grinder dust in an environmentally safe way. Wear
proper face, hand, and body
protection.
Keep
flammables away.
1
Workpiece
3
2
4
90°
1
Make sure workpiece is clean
before welding.
2
Work Clamp
Place as close to the weld as
possible.
10−15°
4
5
6
10−25°
3
4
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten
according to Sections 8-1, and 8-2
or 8-3.
5
Guidelines:
6
1/16 in
3/16 in
Bottom View Of Gas Cup
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.
Tungsten extension is the distance
the tungsten extends out gas cup
of torch.
The tungsten extension should be
no greater than the inside diameter
of the gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
OM-2222 Page 50
9-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
Tilt torch
Remove rod
15°
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
OM-2222 Page 51
9-3. Positioning Torch Tungsten For Various Weld Joints
90°
Butt Weld And Stringer Bead
70°
20°
20°
“T” Joint
70°
10°
20°
40°
Lap Joint
70°
20°
30°
90°
Corner Joint
70°
20°
ST-162 003 / S-0792
OM-2222 Page 52
Notes
OM-2222 Page 53
42
SECTION 10 − PARTS LIST
Hardware is common and
not available unless listed.
PC2
36
36
1
17
35
34
34
37
38
33
41
3
32
31
30
29
FIG.10−2−39
4
5
28
PC1
8
27−PC3
7
6
26
25
9
24
10
11
12
13
23
14
22
15
21
40
20
16
19
43
18
17
.
Figure 10-1. Main Assembly
OM-2222 Page 54
ST-802 005-D
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
400
Non CE
Figure 10-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 195 585 . .
. . . 3 . . . . . . . . . . . . . 138 442 . .
. . . 3 . . . . . . . . . . . . . 179 309 . .
. . . 4 . . . . . . . . . . . . +175 148 . .
. . . . . . . . . . . . . . . . . . . 175 256 . .
. . . 5 . . . . . . . . . . . . . 134 327 . .
. . . 5 . . . . . . . . . . . . . 179 310 . .
. . . 6 . . . . T2 . . . . ♦193 311 . .
. . . 6 . . . . T2 . . . . ♦193 310 . .
. . . . . . . . RC10 . . . . 166 679 . .
. . . 7 . . . . . . . . . . . . ♦187 461 . .
. . . 8 . . . PC1 . . . . . 188 740 . .
. . . 8 . . . PC1 . . . . . 188 734 . .
. . . . . . . . PLG2 . . . . . 115 091 . .
. . . . . . . . PLG3 . . . . . 115 092 . .
. . . . . . . . PLG4 . . . . 131 054 . .
. . . . . . . . PLG5 . . . . . 115 091 . .
. . . . . . . . PLG7 . . . . 130 203 . .
. . . . . . . . PLG8 . . . . . 115 092 . .
. . . . . . . . PLG9 . . . . 131 204 . .
. . . . . . . . PLG10 . . . . . 115 094 . .
. . . 9 . . . . T2 . . . . . 180 873 . .
. . . 9 . . . . T2 . . . . . 189 536 . .
. . . . . . . . PLG10 . . . . 166 680 . .
. . . 10 . . . GS1 . . . . . 133 873 . .
. . . 11 . . . . . . . . . . . . ♦189 033 . .
. . . 12 . . . CB1 . . . . ♦161 078 . .
. . . 13 . . . . . . . . . . . . . 605 227 . .
. . . 14 . . . . . . . . . . . . . 188 570 . .
. . . 15 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . ♦175 282
. . . 17 . . . . . . . . . . . . . 175 138
. . . 18 . . . . . . . . . . . . . 179 625
. . . 18 . . . . . . . . . . . . . 182 561
. . . 19 . . . . . . . . . . . . . 186 440
. . . 19 . . . . . . . . . . . . . 175 213
. . . 20 . . . . . . . . . . . . . 182 445
. . . 21 . . . . . . . . . . . . . 176 226
. . . 22 . . . . S1 . . . . . 128 756
. . . 23 . . . PC2 . . . . . 185 090
. . . . . . . . . . . . . . . . . . . 176 879
. . . . . . . . PLG13 . . . . 131 204
. . . . . . . . PLG14 . . . . . 115 094
. . . . . . . . . . . . . . . . . . . 179 626
. . . 24 . . . . . . . . . . . . +175 132
. . . 25 . . . . . . . . . . . . . 173 693
. . . 26 . . . . . . . . . . . . . 176 736
. . . 27 . . . PC3 . . . . . 190 364
. . . . . . . . DD1-6 . . . . 186 914
. . . . . . . . PLG11 . . . . . 115 091
. . . . . . PLG17, 18 . . 131 054
. . . 28 . . . FM . . . . . 175 084
. . . . . . . . . . . . . . . . . . . 135 635
. . . 29 . . . . . . . . . . . . . 190 542
. . . 30 . . . . . . . . . . . . . 191 172
. . . 30 . . . . . . . . . . . . . 189 490
HANDLE, rubberized carrying . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
LABEL, caution falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 2
LABEL, caution falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
INSULATOR, side RH & LH . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
LABEL, warning general precautionary . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 2
LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . 2
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
BRACKET, mtg aux transformer . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
VALVE, 24VDC 2way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
RECEPTACLE, str dx grd 2P 3W 15A . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CIRCUIT BREAKER, 1P 7A 250VAC . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
NUT, .750-14 knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
PLATE, identification rear
(order by model and serial number) . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . COVER, receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BOX, louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
. . CABLE, pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . 1
. . BUSHING, strain relief .350/.630 ID . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BUSHING, strain relief .472/.787 ID . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . 1
. . NUT, stl locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . SWITCH, tgl 3PST 40A 600VAC (Power Switch) . . . . . . 1 . . . . . 1 . . . . . 1
. . CIRCUIT CARD, assembly . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . SCREW, M5−.8−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . 18 . . . . 18
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BUS BAR, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4 . . . . . 4
. . SCREW, mtg foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4 . . . . . 4
. . CIRCUIT CARD, front panel (consisting of) . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . . . LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . 6 . . . . . 6
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
. . MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . NAMEPLATE, RH (order by model and serial number) . . . . . . . . . 1
. . NAMEPLATE, RH (order by model and serial number) . 1 . . . . . . . . . . . . . 1
OM-2222 Page 55
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
400
Non CE
Figure 10-1. Main Assembly (Continued)
. . . 31
. . . 31
. . . 32
. . . 33
. . . 33
. . . 34
. . . 35
. . . 35
. . . 36
. . . 37
. . . 37
. . . 38
. . . 39
. . . 40
. . . 41
. . . 42
. . . 43
. . . RC2 . . . . . 191 302
. . . RC2 . . . . ♦191 302
. . . RC1 . . . . . 188 186
. . . . . . . . . . . . . 183 565
. . . . . . . . . . . . . 189 489
. . . . . . . . . . . . . 185 703
. . . . . . . . . . . . . 188 192
. . . . . . . . . . . . . 187 235
. . . C7,8 . . . . 186 543
. . . . . . . . . . . . . 190 569
. . . . . . . . . . . . . 189 228
. . . . . . . . . . . . . 186 952
. . . . . . . . . . . . . Fig 10-2
. . . . . . . . . . . . . 182 108
. . . . . . . . . . . . . 190 543
. . . . . . . . . . . . . 148 329
. . . . . . . . . . . . . 182 826
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
CONNECTOR & SOCKETS 10-pin . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR & SOCKETS 10-pin . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . .
CONNECTOR & SOCKETS 14-pin . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
NAMEPLATE, LH (order by model and serial number) . . . . . . . . . 1
NAMEPLATE, LH (order by model and serial number) . 1 . . . . . . . . . . . . .
RECEPTACLE, twist lock assembly . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
RECEPTACLE, male gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RECEPTACLE, female gas . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . .
CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . 1
NAMEPLATE, (order by model and serial number) . . . . 1 . . . . . . . . . . . . .
KNOB, encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
WINDTUNNELS w/COMPONENTS . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CABLE, ribbon 24 posn 2.750 . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
LABEL, caution incorrect voltage . . . . . . . . . . . . . . . . . . . 1
LABEL, warning electric shock power cord . . . . . . . . . . . 1
1
1
1
2
1
2
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Optional
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-2222 Page 56
.
Hardware is common and
not available unless listed.
1
2
7
35
6
34
3
4
8
5
11
9
10
33
36
31
32
12
30
13
29
28
27
26
14
15
25
16
24
36
17
23
18
22
21
19
20
ST-802 006-D
Figure 10-2. Windtunnels w/Components
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
400
Non CE
Figure 10-2. Windtunnels w/Components
(Fig 10-1 Item 39)
... 1
... 2
... 3
... 4
... 5
... 6
... 7
... 8
... 9
. . . 10
. . . 11
. . . 12
. . . 13
. . . 14
. . . 15
. . . 16
. . . . . . HD1 . . . . . 182 918
. . . . . . . . . . . . . . . +182 206
. . . . R1,C5,6 . . . 175 194
. . . . . . D1,2 . . . . . 185 775
. . . . . . . . . . . . . . . . 182 208
. . . . . . . T3 . . . . . . 182 667
. . . . . . . . . . . . . . . . 183 073
. . . . . . . . . . . . . . . . 182 499
. . . . . . . . . . . . . . . . 182 806
. . . . . . C3,4 . . . . . 174 980
. . . . . . . T1 . . . . . . 183 014
. . . . . . . L2 . . . . . . 183 009
. . . . . . . L1 . . . . . . 187 522
. . . . . . PC9 . . . . . 187 264
. . . . . . . . . . . . . . . . 187 463
. . . . . . C1 . . . . . 186 549
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
TRANSDUCER, current 400A . . . . . . . . . . . . . . . . . . . 1 . . . . .
WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
TRANSFORMER, coupling . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
INSULATOR, PC card HF . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
ENCLOSURE, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
BRACKET, mtg contactor/capacitor/PC board . . . . . . 1 . . . . .
CAPACITOR, elctlt 2700uf 420VDC . . . . . . . . . . . . . . 2 . . . . .
TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
STABILIZER, output . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
CIRCUIT CARD ASSEMBLY, input filter . . . . . . . . . . . . . . . . . . .
BRACKET, filter board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, polyp .27uf 1000VDC . . . . . . . . . . . . . . 1 . . . . .
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
1
1
1
1
1
1
1
1
1
2
1
1
1
..... 1
OM-2222 Page 57
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
400
Non CE
Figure 10-2. Windtunnels w/Components
(Fig 10-1 Item 39) (Continued)
. . . 17 . . . . . . . . . . . . . . . . 025 248
. . . 18 . . . . . . CT1 . . . . . 175 199
. . . 19 . . . . . . . . . . . . . . . . 177 547
. . . 20 . . . . . . . . . . . . . . . . 175 140
. . . 21 . . . . . . . . . . . . . . . . 181 197
. . . 22 . . . . . . L3,4 . . . . . 175 482
. . . 23 . . . . . . . . . . . . . . . . 109 056
. . . 24 . . . . . . . . . . . . . . . +187 460
. . . 25 . . . . . . . . . . . . . . . . 188 008
. . . 26 . . . . . . . . . . . . . . . . 141 690
. . . 27 . . . . . . PC7 . . . . . 191 397
. . . . . . . . . . . . . F1 . . . . . . 012 633
. . . . . . . . . . . . . . . . . . . . . . 188 109
. . . . . . . . . . . PLG19 . . . . 115 092
. . . . . . . . . . . PLG20 . . . . 131 054
. . . 28 . . . . . . SR1 . . . . . 179 629
. . . 29 . . PM1,2/PC4,5 . 179 628
. . . . . . . . . PLG15, 16 . . 115 094
. . . . . . . . . . . RT1,2 . . . . 173 632
. . . 30 . . . . . . . . . . . . . . . . 173 631
. . . 31 . . . . . . . . . . . . . . . . 182 641
. . . 32 . . . . . . . . . . . . . . . . 185 587
. . . 33 . . . . . . . . . . . . . . . . 175 082
. . . . . . . . . . . . . . . . . . . . . . 173 763
. . . 34 . . . . . . . . . . . . . . . . 188 361
. . . 35 . . . . . . . . . . . . . . . . 175 194
. . . 36 . . . . . . . . . . . . . . . . 185 836
. . . 36 . . . . . . . . . . . . . . . . 185 835
. . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . BUSHING, snap-in CT-mount . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . BRACKET, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . GASKET, DI-DT rubber . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . COIL, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . BAR, support PC card . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . GROMMET, scr No. 8/10 . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . CIRCUIT CARD, HF (consisting of) . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . . . FUSE, mintr gl 1A 250V . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . BUS BAR, diode IGBT . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . BUS BAR, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . CONTACTOR, def prp 40A 7P . . . . . . . . . . . . . . . . . . . 1
. . STAND-OFF, No. 10-32 x 1.418 lg . . . . . . . . . . . . . . . 1
. . Bus Bar, diode heat sink . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . RESISTOR/CAPACITOR ASSEMBLY . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . .
2
1
1
1
1
2
2
1
1
2
1
1
2
1
1
1
1
2
2
1
1
1
1
1
2
+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-2222 Page 58
Effective January 1, 1999
(Equipment with a serial number preface of “KK” or newer)
Warranty Questions?
Call
1-800-4-AMILLER
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.
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.
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate 185
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’s True Blue Limited Warranty shall not apply to:
1.
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.
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.
2.
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
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.
1.
5 Years Parts − 3 Years Labor
*
*
2.
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
3 Years — Parts and Labor
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
*
*
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
*
*
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor
*
Motor Driven Guns (w/exception of Spoolmate
185)
*
*
Process Controllers
Positioners and Controllers
*
*
Automatic Motion Devices
Robots
*
*
IHPS Power Sources
Water Coolant Systems
*
*
*
HF Units
Grids
Spot Welders
*
*
Load Banks
SDX Transformers
*
*
Miller Cyclomatic Equipment
Running Gear/Trailers
*
Plasma Cutting Torches (except APT, ZIPCUT &
PLAZCUT Models)
*
*
Deutz Engines (outside North America)
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
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 1/99
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
To locate distributor nearest you call
1-800-4-A-Miller.
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 1999 Miller Electric Mfg. Co.
9/98
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