Syncrowave 250DX 350LX Operators Manual

Syncrowave 250DX 350LX Operators Manual

Visit our website at

www.MillerWelds.com

OM-363

November 2004

Processes

TIG (GTAW) Welding

213117F

Stick (SMAW) Welding

Description

Arc Welding Power Source

And w/Integrated Cooler

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,

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

System Standard.

there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem.

Warranty and service information for your particular model are also provided.

Working as hard as you do

− every power source from

Miller is backed by the most hassle-free warranty in the business.

Miller Electric manufactures a full line of welders and welding related equipment.

For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Mil_Thank 7/03

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance

1-4. California Proposition 65 Warnings

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

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

1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil.

2-4. Principales normes de sécurité

. . . . . . . . . . .

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

2-5. Information sur les champs électromagnétiques

SECTION 3 − DEFINITIONS

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

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

3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Torch/Cable Holder Label

3-3. Symbols And Definitions

SECTION 4 − INSTALLATION

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

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

4-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Cooler Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Welding Power Source Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Duty Cycle And Overheating

4-6. Volt-Ampere Curves

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

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

4-7. Weld Output Terminals And Selecting Cable Sizes

4-8. Remote 14 Receptacle Information

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

4-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Cooler Connections And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. TIG Connections With A Water-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. TIG Connections With A Two-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. TIG Connections With A One-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) . . . . . . . . . . . . .

4-15. Front Panel Display For TIG AC

4-16. Stick Connections

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

4-17. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)

4-18. Front Panel Display For Stick AC

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

4-19. Electrical Service Guide

4-20. Placing Jumper Links

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

4-21. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5-1. Controls (350 LX Nameplates Shown)

5-2. Output Selector Switch

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

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

5-3. Process Control

5-4. Amperage Control

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5-5. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. 4T, 4T Momentary, And Mini Logoic Trigger Operation (Requires Optional Sequence Controls) . . . . .

5-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Selecting TIG Starting Characteristics Using Syncro-Startt Technology

5-9. Start Mode

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5-10. Balance/DIG Control

5-11. Preflow Time Control

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5-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models) . . . . . . . . . . . . . . . . . . . . .

1

9

10

11

7

8

8

9

9

4

5

5

5

1

1

3

3

4

25

26

27

29

30

31

31

33

40

42

43

44

33

33

34

36

38

46

19

20

20

21

22

23

24

14

15

17

17

18

11

12

12

12

TABLE OF CONTENTS

5-13. Sequence Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14. Initial Time Control And Initial Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15. Final Slope Control And Final Amperage Control

5-16. Spot Time Control

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5-17. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-18. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Welding Power Source Maintenance

6-2. Routine Cooler Maintenance

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

6-3. Circuit Breaker CB1

6-4. Adjusting Spark Gaps

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

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

SECTION 7 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Troubleshooting The Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Troubleshooting The Welding Coolant System

SECTION 8 − ELECTRICAL DIAGRAM

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

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

SECTION 9 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Incorrect Installation

9-3. Correct Installation

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

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SECTION 10 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING . .

10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . .

10-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

59

60

61

61

61

62

54

55

56

57

59

59

47

48

49

49

50

51

52

52

52

53

53

54

Declaration of Conformity For

European Community (CE) Products

NOTE

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

Manufacturer’s Name:

Manufacturer’s Address:

Miller Electric Mfg. Co.

1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product:

Syncrowave

R

250 DX

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

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

Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Standards

Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.

IEC 60974-10 August 2002

Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1

Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1

Insulation Coordination For Equipment Within Low-Voltage Systems:

Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1

European Contact:

Telephone:

Fax:

Mr. Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l.

Via Privata Iseo 6/E

20098 San Giuliano

Milanese, Italy

39(02)98290-1

39(02)98290−203 dec_stat_2/04

Declaration of Conformity For

European Community (CE) Products

NOTE

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

Manufacturer’s Name:

Manufacturer’s Address:

Miller Electric Mfg. Co.

1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product:

Syncrowave

R

350 LX

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

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

Machinery Directives: 98/37EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Standards

Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements.

IEC 60974-10 August 2002

Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1

Degrees of Protection Provided By Enclosures (IP Code): IEC 60529 Ed. 2.1

Insulation Coordination For Equipment Within Low-Voltage Systems:

Part 1: Principles, Requirements And Tests. IEC 60664-1 Ed. 1.1

European Contact:

Telephone:

Fax:

Mr. Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l.

Via Privata Iseo 6/E

20098 San Giuliano

Milanese, Italy

39(02)98290-1

39(02)98290−203 dec_stat_2/04

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _8/03

1-1. Symbol Usage

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

Y Marks a special safety message.

.

Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in

the Safety Standards listed in Section 1-5. Read and follow all

Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions to avoid the hazards.

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

D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

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

D Insulate work clamp when not connected to workpiece to prevent contact with any metal object.

D Do not connect more than one electrode or work cable to any single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on unit.

D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D When making input connections, attach proper grounding conductor first − double-check connections.

D Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

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

D If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

OM-363 Page 1

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your helmet.

D Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

D Wear approved safety glasses with side shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or torch.

MAGNETIC FIELDS

can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise level is high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder − explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in use or connected for use.

D Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-363 Page 2

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

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

D Do not install unit near flammables.

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

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards closed and securely in place.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and support unit.

D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling boards or parts.

D Use proper static-proof bags and boxes to store, move, or ship PC boards.

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.

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.

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

D If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do so.

D Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

1-4. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health &

Safety Code Section 25249.5 et seq.)

Y Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

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

For Gasoline Engines:

Y Engine exhaust contains chemicals known to the State of

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

For Diesel Engines:

Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and other reproductive harm.

OM-363 Page 3

1-5. Principal Safety Standards

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

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

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

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

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

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

sparky.org).

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

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

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

Canadian Standards Association, Standards Sales, 178 Rexdale

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

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

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

Practice For Occupational And Educational Eye And Face Protection,

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

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

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

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

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

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

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

312−353−2220, website: www.osha.gov).

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from operator as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-363 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT

UTILISATION

som_fre 8/03

2-1. Signification des symboles

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

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

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

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

Y Identifie un message de sécurité particulier.

.

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

2-2. Dangers relatifs au soudage à l’arc

Y Les symboles ci-après sont utilisés tout au long du présent

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

contenu des normes de sécurité mentionnées à la section 2-5.

Lire et respecter toutes ces normes.

Y L’installation, l’utilisation, l’entretien et les réparations ne doi-

vent être confiés qu’à des personnes qualifiées.

Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,

en particulier les enfants.

LES DÉCHARGES ÉLECTRIQUES peuvent être mortelles.

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

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

En soudage semi−automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal mis à la terre présente un danger.

D Ne jamais toucher aux pièces électriques sous tension.

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

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

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

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

D Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).

D Installer et mettre à la terre correctement l’appareil conformément à son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée

à une prise correctement mise à la terre.

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

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

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

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

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

D Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode d’une autre machine.

D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le− champ les pièces endommagées. Entretenir l’appareil conformément au présent manuel.

D Porter un harnais de sécurité quand on travaille en hauteur.

D Maintenir solidement en place tous les panneaux et capots.

D Fixer le câble de retour de façon à obtenir un bon contact métal sur métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

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

Il subsiste un COURANT CONTINU IMPORTANT dans les convertisseurs après la suppression de l’alimentation électrique.

D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions

énoncées à la section Entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

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

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

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

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

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

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

D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

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

OM-363 Page 5

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

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

Des étincelles sont projetées pendant le soudage.

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

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

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

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

D Porter des vêtements de protection en matière durable et ignifuge

(cuir ou laine) et des chaussures de sécurité.

LE SOUDAGE peut causer un incendie ou une explosion.

Le soudage effectué sur des récipients fermés tels que des réservoirs, des fûts ou des conduites peut causer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, les pièces chaudes et les équipements chauds peuvent causer des incendies et des brûlures. Le contact accidentel de l’électrode avec tout objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.

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

D Placer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées.

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

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

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

D Ne pas souder des récipients fermés tels que des réservoirs, des fûts ou des conduites, à moins qu’ils n’aient été préparés conformément à l’AWS F4.1 (voir les normes de sécurité).

D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

D En cas de non utilisation, enlever la baguette d’électrode du porte−

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

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

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

LES PARTICULES PROJETÉES peuvent blesser les yeux.

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

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

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

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

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

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

LES PIÈCES CHAUDES peuvent causer des brûlures graves.

D Ne pas toucher les pièces chaudes à main nue.

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

LES CHAMPS MAGNÉTIQUES peuvent perturber le fonctionnement des stimulateurs cardiaques.

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

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

LE BRUIT peut affecter l’ouïe.

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

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

Les BOUTEILLES endommagées peuvent exploser.

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

D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des chocs mécaniques, du laitier, des flammes nues, des étincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte−bouteilles pour les empêcher de tomber ou de se renverser.

D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.

D Ne jamais poser une torche de soudage sur une bouteille de gaz.

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

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

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

état, ainsi que les pièces connexes.

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

D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille

D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA, mentionnées dans les normes de sécurité.

OM-363 Page 6

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil.

Risque D’INCENDIE OU D’EXPLO-

SION

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

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

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

LA CHUTE DE L’APPAREIL peut blesser.

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

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

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

L’EMPLOI EXCESSIF peut FAIRE

SURCHAUFFER L’ÉQUIPEMENT.

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

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

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

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les circuits imprimés.

D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimés.

LES PIÈCES MOBILES peuvent causer des blessures.

D Se tenir à l’écart des pièces mobiles.

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

LES FILS DE SOUDAGE peuvent causer des blessures.

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

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

LES ORGANES MOBILES peuvent causer des blessures.

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

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

LE RAYONNEMENT HAUTE FRÉ-

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

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

D Ne demander qu’à des personnes qualifiées familiarisées avec les

équipements électroniques de faire fonctionner l’installation.

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

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

D Faire régulièrement contrôler et entretenir l’installation.

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

LE SOUDAGE À L’ARC peut causer des interférences.

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

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

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

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

électronique sensible.

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

D En cas d’interférences après exécution des directives précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à distance.

D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

OM-363 Page 7

2-4. Proposition californienne 65 Avertissements

Y Les équipements de soudage et de coupage produisent des

fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants)

Y Les batteries, les bornes et autres accessoires contiennent du

plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation.

Pour les moteurs à essence :

Y Les gaz d’échappement des moteurs contiennent des

produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation.

Pour les moteurs diesel :

Y Les gaz d’échappement des moteurs diesel et certains de

leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations congénitales ou autres problèmes de procréation.

2-5. Principales normes de sécurité

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

353−2220, site Web : www.osha.gov).

2-6. Information sur les champs électromagnétiques

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

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

électromagnétiques pendant le soudage ou le coupage.

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

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

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

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

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

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

Consignes relatives aux stimulateurs cardiaques :

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

OM-363 Page 8

SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions

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

1 Electric shock from welding electrode or wiring can kill.

1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

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

1.3 Disconnect input plug or power before working on machine.

2 Breathing welding fumes can be hazardous to your health.

2.1 Keep your head out of the fumes.

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

2.3 Use ventilating fan to remove fumes.

3 Welding sparks can cause explosion or fire.

3.1 Keep flammables away from welding.

Do not weld near flammables.

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

3.3 Do not weld on drums or any closed containers.

4 Arc rays can burn eyes and injure skin.

4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

5 Become trained and read the instructions before working on the machine or welding.

6 Do not remove or paint over (cover) the label.

1 1.1

1.2

1.3

4 4.1

2 2.1

2.2

2.3

3 3.1

3.2

5

3.3

6

3-2. Torch/Cable Holder Label

1

3

2

197 310-A

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

2 Electric shock from wiring can kill.

3 Do not operate unit or reach inside when torch/cable holder is removed.

4 Do not exceed 25 lb (12.4 kg) maximum load on gun/cable holder or holder may break.

OM-363 Page 9

3-3. Symbols And Definitions

NOTE

Some symbols are found only on CE products.

A

Amperes

V

Volts

Output

Protective Earth

(Ground)

Postflow Timer

Panel−Local

Do Not Switch

While Welding

Circuit Breaker

Gas Tungsten Arc

Welding (GTAW)

Arc Force (DIG)

Shielded Metal Arc

Welding (SMAW)

Background Amps

Gas (Supply)

Alternating Current

Preflow Timer

Gas Output

Remote

High Frequency -

Start

High Frequency -

Continuous

Gas Input

Temperature

Water Input

Water Output

Increase/Decrease

Of Quantity

Direct Current On Off Percent

Balance Control Maximum Cleaning

Maximum

Penetration

Electrode Positive

Electrode

Negative

U

0

Rated No Load

Voltage (Average)

U

1

I

1

Primary Current

I

2

IP

Degree Of

Protection

I

1eff

Final Slope Meter Single-Phase

Primary Voltage

Rated Welding

Current

Maximum Effective

Supply Current

I

U

2

X

1max

Conventional Load

Voltage

Duty Cycle

Rated Maximum

Supply Current

1

1

Line Connection

Single-Phase

Combined AC/DC

Power Source

Hz

Hertz

Work Thickness Gauge Spark Gap Electrode

S

Seconds

Pulse Percent On

Time

Trigger Hold

OM-363 Page 10

Final Amperage

Spot Time

Pulser On-Off

Initial Time

Lift-Arct

4T

Pulse Frequency

Initial Amperage

4 Step Trigger Operation Sequence

Input

SECTION 4 − INSTALLATION

4-1. Selecting A Location

Movement

1

OR

2

Location And Airflow

1

5

250 DX Models

3

SERIAL NO.

STOCK NO.

XXXXXXX3

XXXXXXXXXXXXXX4

LR5071

C

®

US

PROTECTED B Y ONE OR MORE OF THE

FOLLOWING US. PATENTS:

XXXXX05

XXXXX10

XXXXX06

XXXXX11

XXXXX07

XXXXX15

XXXXX09

XXXXX21

XXXXX24 XXXXX25 XXXXX26 XXXXX32

XXXXX42 XXXXX47 XXXXX48

EVIDENCE OF LABEL T AMPERING VOIDS WARRANTY

350 LX Models

3

SERIAL NO.

STOCK NO.

XXXXXXX3

XXXXXXXXXXXXXX4

LR5071

C

®

US

PROTECTED B Y ONE OR MORE OF THE

FOLLOWING US. PATENTS:

XXXXX05

XXXXX10

XXXXX06

XXXXX11

XXXXX07

XXXXX15

XXXXX09

XXXXX21

XXXXX24 XXXXX25 XXXXX26 XXXXX32

XXXXX42 XXXXX47 XXXXX48

EVIDENCE OF LABEL T AMPERING VOIDS WARRANTY

18 in

(460 mm)

18 in (460 mm)

4

4

Y Falling Unit Can Cause Injury.

S

Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

S

Use equipment of adequate capacity to lift and support unit.

S

If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to move unit.

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

3 Serial Number/Patent Label

4 Rating Label

Use rating label to determine input power needs.

5 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.

Y Be careful when placing or moving

unit over uneven surfaces.

Ref. 117 264-C / 803 584-A / 216 202-D / 216 203-C / 208 998

OM-363 Page 11

4-2. Dimensions And Weights

A

H

B

803 616-A

D

E

B

C

Height

Width

Length

A

F

G

36-1/4 in (921 mm)

23 in (584 mm)

28 in (711 mm)

25 in (635 mm)

1-25/64 in (35 mm)

1-5/8 in (41 mm)

22 in (559 mm)

20 in (508 mm)

22-1/4 (565 mm)

1-1/8 in (29 mm)

H 1/2 in (13 mm) Dia

Weight

400 lbs (181 kg) For 250 DX Models

496 lbs (225 kg) For 350 LX Models

4-3. Cooler Specifications

Cooler Tank Capacity 3 gallons (11.4 L)

Coolant Flow Rate 1 liter per minute (1.1 quart)

Use With Torches Rated Up To 400 Amperes

Cooler Specifications

4-4. Welding Power Source Specifications

A. For 350 LX Models

Rated

Welding

Output

Amperes Input at AC Balanced Rated Load Output,

50/60 Hz, Single-Phase

PFC

**

200V 220V 230V 400V 440V 460V 520V 575V

KVA KW

103

2.2*

110

2.0*

57

1.5*

52

1.2*

55

1.7*

43

1.0*

42

1.1*

25.0

0.9*

10.6

0.6*

NEMA Class I

(60) − 300

Amperes, 32

Volts AC, 60%

Duty Cycle

No

PFC

With

PFC

125

3.3*

92

77*

NEMA Class II

(40) − 350

Amperes, 34

Volts AC, 40%

Duty Cycle

No

PFC

With

PFC

*While idling

**Power Factor Correction

146

3.3*

114

77*

77

67*

120

2.2*

95

67*

78

69*

128

2.6*

94

69*

40

36*

66

2.5*

49

36*

39

33*

60

1.2*

47

33*

38

34*

65

1.7*

47

34*

33

28*

51

1.0*

40

28*

31

27.2*

50

1.1*

38

27.2*

18.0

16.6*

29.5

0.9*

21.7

16.6*

10.5

0.6*

13.7

0.4*

13.3

0.6*

Amperage

Range

Max

OCV

OM-363 Page 12

B. For 250 DX Models

Amperes Input at AC Balanced Rated

Load Output, 60 Hz, Single-Phase

Rated

Welding Output PFC**

NEMA Class I (40) −

200 Amperes, 28

Volts AC, 60% Duty

Cycle

No

PFC

With

PFC

NEMA Class II (40) −

250 Amperes, 30

Volts AC, 40% Duty

Cycle

*While idling

**Power Factor Correction

No

PFC

With

PFC

200V

88

*3.3

60

*55.3

110

*3.3

82

*55.3

230V

77

*2.8

52

*49.5

96

*2.8

71

*49.5

460V

38

*1.5

26

*24.5

48

*1.5

35

*24.5

575V

31

*1.1

21

*19.6

38

*1.1

28

*19.6

KVA

17.6

*.59

12.06

*11.2

21.98

*.59

16.32

*11.2

Amperes Input at AC Balanced Rated

Load Output, 50/60 Hz, Single-Phase

Rated

Welding Output

PFC**

NEMA Class I (40) −

200 Amperes, 28

Volts AC, 60% Duty

Cycle

No

PFC

With

PFC

NEMA Class II (40) −

250 Amperes, 30

Volts AC, 40% Duty

Cycle

*While idling

**Power Factor Correction

No

PFC

With

PFC

220V

82

*3.0

61

*45.9

100

*3.0

81

*45.9

400V

45

*1.6

34

*25.1

55

*1.6

44

*25.1

440V

41

*1.4

31

*22.8

50

*1.4

40

*22.8

520V

35

*1.2

26

*23.2

42

*1.2

34

*23.2

KVA

17.6

*.59

12.06

*11.2

21.98

*.59

16.32

*11.2

KW

8.6

*.29

8.11

*.39

11.76

*.29

11.81

*1.93

KW

8.6

*.29

8.11

*.39

11.76

*.29

11.81

*1.93

Amperage

Range

3 − 310A

3 − 310A

3 − 310A

3 − 310A

Amperage

Range

3 − 310A

3 − 310A

3 − 310A

3 − 310A

Max

OCV

80V

80V

80V

80V

Max

OCV

80V

80V

80V

80V

Amperes Input at AC Balanced Rated

Load Output, 50 Hz, Single-Phase

Rated

Welding Output

PFC**

NEMA Class I (40) −

175 Amperes, 27

Volts AC, 60% Duty

Cycle

No

PFC

With

PFC

NEMA Class II (40) −

225 Amperes, 29

Volts AC, 40% Duty

Cycle

*While idling

**Power Factor Correction

No

PFC

With

PFC

200V

80

*3.3

52

*55.3

101

*3.3

74

*55.3

230V

69

*2.8

45

*49.5

88

*2.8

64

*49.5

460V

35

*1.5

22

*24.5

44

*1.5

32

*24.5

575V

28

*1.1

18

*19.6

35

*1.1

26

*19.6

KVA

15.9

*.59

10.3

*11.2

20.2

*.59

14.7

*11.2

KW

7.4

*.29

7.3

*.39

10.2

*.29

10.1

*1.93

Amperage

Range

3 − 310A

3 − 310A

3 − 310A

3 − 310A

OM-363 Page 13

Max

OCV

80V

80V

80V

80V

4-5. Duty Cycle And Overheating

250 DX Models

40% Duty Cycle At 250 Amperes

4 Minutes Welding

Overheating

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

If unit overheats, output stops, front panel voltmeter/ammeter displays a HLP3 or HLP5 message (see

Section 7-1), and cooling fans run.

Wait fifteen minutes for unit to cool.

Reduce amperage or duty cycle before welding.

Y Exceeding duty cycle can

damage unit and void warranty.

60% Duty Cycle At 200 Amperes

6 Minutes Resting

0

Minutes

15

6 Minutes Welding

OR

A

Reduce Duty Cycle

4 Minutes Resting duty1 4/95 / Ref. 116 198

350 LX Models

40% Duty Cycle At 350 Amperes

4 Minutes Welding

Overheating

60% Duty Cycle At 300 Amperes

6 Minutes Resting

0

Minutes

15

6 Minutes Welding

OR

A

Reduce Duty Cycle

4 Minutes Resting duty1 4/95 / 190 276

OM-363 Page 14

4-6. Volt-Ampere Curves

A. For 250 DX Models

Non CE Models

The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.

80

70

60

50

40

30

20

10

0

0 50 100 150 200 250 300 350 400 450

AMPS

20

10

0

0

80

70

60

50

40

30

50 100 150 200 250 300 350 400 450

AMPS

194 385-A / 194 384-A

CE Models

80

70

60

50

40

30

20

10

0

0 50 100 150 200 250 300 350 400 450

AMPS

20

10

0

0

80

70

60

50

40

30

50 100 150 200 250 300 350 400 450

AMPS

205 631 / 205 632

OM-363 Page 15

B. For 350 LX Models

350 Amperes Models

The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.

ssb1.1 10/91 − ST-190 277 / ST-190 278

OM-363 Page 16

4-7. Weld Output Terminals And Selecting Cable Sizes

Y ARC WELDING can cause Electromagnetic Interference.

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

Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Weld Output

Terminals

Y Turn off power before

connecting to weld output terminals.

Y Do not use worn, dam-

aged, undersized, or poorly spliced cables.

Welding

Amperes

10 − 60%

Duty

Cycle

60 − 100%

Duty

Cycle

10 − 100% Duty Cycle

100

150

200

4

3

3

4

3

2

4

2

1

3

1

1/0

2

1/0

2/0

1

2/0

3/0

250

300

350

2

1

1/0

1

1/0

2/0

1/0

2/0

3/0

2/0

3/0

4/0

3/0

4/0

2-2/0

4/0

2-2/0

2-3/0

2-2/0

2-3/0

2-3/0

Electrode

Work

Ref. 803 588-A

400

500

1/0

2/0

2/0

3/0

3/0

4/0

4/0

2-2/0

2-2/0

2-3/0

2-3/0

2-4/0

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere

*Select weld cable size for pulsing application at peak amperage value..

2-4/0

3-3/0

1/0

3/0

4/0

2-2/0

2-3/0

2-4/0

1/0

3/0

4/0

2-4/0

3-3/0

S-0007-D

4-8. Remote 14 Receptacle Information

Y Turn off power before

connecting to receptacle.

B

A

K

J

I

D M G

Ref. 803 588-A

OUTPUT

CONTACTOR

A

REMOTE

OUTPUT

CONTROL

A/V

AMPERAGE

VOLTAGE

GND

Socket*

A

B

C

F

H

K

D

E

Socket Information

Contactor control 24 volts dc.

Contact closure to A completes 24 volts dc contactor control circuit and enables output.

Output to remote control; 0 to +10 volts dc output to remote control.

Remote control/feedback circuit common.

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

Current feedback; +1 volt dc per 100 amperes.

Voltage feedback; +1 volt dc per 10 volts output.

Chassis common.

*The remaining sockets are not used.

OM-363 Page 17

4-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle

2

Tools Needed:

5/8, 3/4, 1-1/8 in

5

4

3

Y Turn Off power before con-

necting to receptacle.

1 Gas Valve In Connection

Located on rear of unit.

2 Gas Valve Out Connection

Connections have 5/8-18 righthand threads.

3 Cylinder Valve

Open valve slightly so gas flow blows dirt from valve. Close valve.

4 Regulator/Flow Gauge

Connect regulator/flow gauge to gas cylinder.

Connect customer supplied gas hose between regulator/flow gauge and gas in fitting.

5 Flow Adjust

Typical flow rate is 20 cfh (cubic feet per hour).

6 115 V 15 Amp AC Receptacle

Receptacle is protected from overload by circuit breaker CB1 (see

Section 6-3).

Rear View

Front View

1

6

Ref. 803 588-A / Ref. 803 585-A / Ref. 157 858

OM-363 Page 18

4-10. Cooler Connections And Operation

Tools Needed:

5/8, 3/4, 1-1/8 in

1

2

Cooler Tank Capacity: 3 gallons (11.4 L)

Cooler Flow Rate: 1 liter per minute (1.1 qt)

Use With Torches Rated Up To 400 Amperes

Application

GTAW Or Where

HF* Is Used

MILLER Low Conductivity

Coolant No. 043 810**;

Distilled Or Deionized Water

OK Above 32

°

F (0

°

C)

Coolant

*HF: High Frequency Current

**MILLER coolants protect to -37

°

F (-38

°

C) and resist algae growth.

Y Use of any coolant other than those listed in the table voids the warranty on any parts

that come in contact with the coolant (pump, radiator, etc.).

Y Turn Off power before con-

necting to coolant fittings.

1 Coolant Tank Cap

Use table below to select proper coolant. Remove cap and add coolant. Fill to capacity. Keep coolant level full.

Connect torch as shown in Section

4-11.

Priming

Initial setup requires priming of the coolant system before operation.

To prime the system, proceed as follows:

2 Process Control Switch

For cooler operation, place Process Control switch in the GTAW

(TIG) position according to Section

5-3.

Press and HOLD the Process Control switch. After 2 seconds the voltmeter displays [CLR] to indicate system priming has initiated.

Continue to hold the Process Control switch until the amp meter displays [FLO] to indicate priming is complete and adequate flow has been detected (approx. 40 seconds).

Operation

Cooler will activate when a valid arc is detected. A system pressure switch will detect and monitor coolant flow. If flow is not detected within

5 seconds of welding, weld output stops, and Help Message 19 is displayed on the volt/amp meters (see

Section 7-1).

During normal operation cooler will continue to operate for 20 seconds after welding arc ends, or until the coolant temperature is adequately reduced.

Changing A Water-Cooled Torch

Y Turn Off power before mak-

ing torch and coolant connections.

Connect new torch and follow priming procedure described above. To avoid a Help Message Code, press and hold Process Control switch for approximately 20 seconds to ensure the torch is completely primed, even if amp meter displays [FLO] sooner.

OM-363 Page 19

4-11. TIG Connections With A Water-Cooled Torch

6

8

7

2

3

5

4

1

Tools Needed:

11/16, (21 mm)

803 601-B

Y Turn Off power before making con-

nections.

1 Gas-In Connection

Connect gas hose from gas supply to gasin connector.

2 Output Selector Switch (See Section

5-2)

Switch is shown in DCEN (direct current electrode negative) position for TIG HF Impulse DCEN welding. For front panel con-

trol dispay, see Section 4-14. For TIG AC

welding, place switch in AC position. For

TIG AC front panel control dispay, see Sec-

tion 4-15.

3 Electrode Weld Output Terminal

Connect TIG torch to electrode weld outout terminal.

4 Work Weld Output Terminal

Connect work lead to work weld output terminal.

5 Remote 14 Receptacle

Connect desired remote control to Remote

14 receptacle (see Section 4-8).

6 Water-In (From Torch) Connection

Connect torch water-out (red) hose to welding power source water-in connection.

7 Gas−Out Connection

Connect torch gas hose to gas-out fitting.

8 Water-Out (To Torch) Connection

Connect torch water-in (blue) hose to welding power source water-out connection.

4-12. TIG Connections With A Two-Piece Air-Cooled Torch

2

6

5

4

3

1

11/16, (21 mm)

Tools Needed:

Y Turn Off power before making

connections.

1 Gas-In Connection

Connect gas hose from gas supply to gas-in connection.

2 Output Selector Switch (See

Section 5-2)

Switch is shown in DCEN (direct current electrode negative) position for

TIG HF Impulse DCEN welding. For front panel control dispay, see Section

4-14. For TIG AC welding, place switch

in AC position (see Section 5-2). For

TIG AC front panel control dispay, see

Section 4-15.

3 Work Weld Output Terminal

Connect work lead to work weld output terminal.

4 Remote 14 Receptacle

Connect desired remote control to Re-

mote 14 receptacle (see Section 4-8).

5 Electrode Weld Output Terminal

Connect TIG torch to electrode weld output terminal.

6 Gas-Out Connection

Connect torch gas hose to gas-out fitting.

803 586-B

OM-363 Page 20

4-13. TIG Connections With A One-Piece Air-Cooled Torch

6

2

5

4

3

1

Tools Needed:

11/16, (21 mm)

Y Turn Off power before making

connections.

1 Gas-In Connection

Connect gas hose from gas supply to gas−in connection.

2 Output Selector Switch (See

Section 5-2)

Switch is shown in DCEN (direct current electrode negative) position for

TIG HF Impulse DCEN welding. For front panel control dispay, see Section

4-14. For TIG AC welding, place switch

in AC position (see Section 5-2). For

TIG AC front panel control dispay, see

Section 4-15.

3 Work Weld Output Terminal

Connect work lead to work weld output terminal.

4 Remote 14 Receptacle

Connect desired remote control to Re-

mote 14 receptacle (see Section 4-8).

5 Electrode Weld Output Terminal

Connect TIG torch to electrode weld output terminal.

6 Gas-Out Connection

Connect torch gas hose to gas-out fitting.

803 615-A

OM-363 Page 21

4-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)

1 Front Panel

Correct front panel display for basic TIG HF Impulse DCEN welding.

.

For all front panel switch pad controls: press switch pad to turn on light and enable function.

NOTE: Green on nameplate indicates a TIG function (see Section

5-1 for description of controls).

1

(CE Nameplate)

1

OM-363 Page 22

4-15. Front Panel Display For TIG AC

1 Front Panel

Correct front panel display for basic TIG AC welding.

.

For all front panel switch pad controls: press switch pad to turn on light and enable function.

NOTE: Green on nameplate indicates a TIG function (see Sec-

tion 5-1 for description of con-

trols).

1

(CE Nameplate)

1

OM-363 Page 23

4-16. Stick Connections

2

4

3

1

Tools Needed:

11/16, (21 mm), 3/4 in

Y Turn Off power before mak-

ing connections.

1 Work Weld Output Terminal

Connect work lead to work weld output terminal.

2 Electrode Weld Output

Terminal

Connect electrode holder to electrode weld outout terminal.

3 Remote 14 Receptacle

If desired, connect remote control to Remote 14 receptacle (see Sec-

tion 4-8).

4 Output Selector Switch (See

Section 5-2)

Switch is shown in DCEP (direct current electrode positive) position for Stick DCEP welding. For front panel control dispay, see Section

4-17. For Stick AC welding, place

switch in AC position. For Stick AC front panel control dispay, see Sec-

tion 4-18.

803 587-A

OM-363 Page 24

4-17. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)

1 Front Panel

Correct front panel display for basic Stick DCEP welding.

.

For all front panel switch pad controls: press switch pad to turn on light and enable function.

NOTE: Gray on nameplate indicates a Stick function (see Sec-

tion 5-1 for description of con-

trols).

1

(CE Nameplate)

1

OM-363 Page 25

4-18. Front Panel Display For Stick AC

1 Front Panel

Correct front panel display for basic Stick AC welding.

.

For all front panel switch pad controls: press switch pad to turn on light and enable function.

NOTE: Gray on nameplate indicates a Stick function (see Sec-

tion 5-1 for description of con-

trols).

1

(CE Nameplate)

1

OM-363 Page 26

4-19. Electrical Service Guide

A. For 250 DX Models

NOTE

All values in both tables were calculated at 60% duty cycle.

NOTE

Actual input voltage cannot exceed

±

10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range, damage to unit may occur.

50/60 Hertz Models

Input Voltage

Input Amperes At Rated Output*

200

88

220

82

Without Power Factor Correction

230

77

400

45

440

41

460

38

520

35

575

31

Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes Circuit Breaker

1

Time-Delay Fuse

2

Normal Operating (Fast) Fuse

3

125

125

125

125

125

125

70

70

60

60

60

60

50

50

45

45

Min Input Conductor Size In AWG 4

Max Recommended Input Conductor Length In

Feet (Meters)

Min Grounding Conductor Size In AWG

4

4

167

(51)

6

137

(42)

6

153

(47)

8

305

(93)

8

369

(112)

10

281

(86)

10

352

(107)

10

439

(134)

6 6 6 8 10 10 10 10

* Input amperes at rated output is the amperage draw for that particular input voltage if the machine is run at its rated welding

output (see Section 4-4 for rated welding output).

Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.

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

3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

50/60 Hertz Models

Input Voltage

Input Amperes At Rated Output*

200

60

220

61

With Power Factor Correction

230

52

400

34

440

31

460

26

520

26

575

21

Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes Circuit Breaker

1

Time-Delay Fuse

2

Normal Operating (Fast) Fuse

3

Min Input Conductor Size In AWG 4

Max Recommended Input Conductor Length In

Feet (Meters)

90

90

8

87 (26)

90

90

8

102

(31)

80

80

8

115

(35)

50

50

10

226

(69)

45

45

10

274

(84)

40

40

10

308

(94)

40

40

10

383

(117)

30

30

12

295

(90)

Min Grounding Conductor Size In AWG 4

8 8 8 10 10 10 10 12

* Input amperes at rated output is the amperage draw for that particular input voltage if the machine is run at its rated welding

output (see Section 4-4 for rated welding output).

Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.

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

3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

OM-363 Page 27

B. For 350 LX Models

NOTE

NOTE

All values in both tables were calculated at 60% duty cycle.

Actual input voltage cannot exceed

±

10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range, damage to unit may occur.

50/60 Hertz Models

Input Voltage

Input Amperes At Rated Output*

Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes Circuit Breaker

1

Time-Delay Fuse

2

Normal Operating (Fast) Fuse

3

Min Input Conductor Size In AWG

4

Max Recommended Input Conductor Length In

Feet (Meters)

Min Grounding Conductor Size In AWG 4

200

125

150

175

3

151

(46)

6

125

175

3

182

(56)

6

220

103

Without Power Factor Correction

230

110

400

57

440

52

460

55

520

43

125

175

4

171

(52)

6

70

90

8

246

(75)

8

70

90

8

298

(91)

8

575

42

60

80

8

326

(99)

8

60

70

8

416

(127)

8

50

70

8

509

(155)

8

* Input amperes at rated output is the amperage draw for that particular input voltage if the machine is run at its rated welding

output (see Section 4-4 for rated welding output).

Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.

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

3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

50/60 Hertz Models

Input Voltage

Input Amperes At Rated Output*

200

92

Max Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes Circuit Breaker

1

Time-Delay Fuse

2

110

Normal Operating (Fast) Fuse

3

125

Min Input Conductor Size In AWG

4

Max Recommended Input Conductor Length In

Feet (Meters)

4

145

(44)

220

77

100

125

6

119

(36)

With Power Factor Correction

230

78

90

125

6

130

(40)

400

40

50

70

8

263

(80)

440

39

50

60

8

318

(97)

460

38

45

60

8

347

(106)

520

33

40

50

10

300

(91)

575

31

35

45

10

367

(112)

Min Grounding Conductor Size In AWG 4

6 6 6 8 10 10 10 10

* Input amperes at rated output is the amperage draw for that particular input voltage if the machine is run at its rated welding

output (see Section 4-4 for rated welding output).

Reference: 1999 National Electrical Code (NEC)

1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.

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

3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

OM-363 Page 28

4-20. Placing Jumper Links

2

Label found on 250 DX models with the following stock numbers:

907194, 907194-021 and, 907194-031

Label found on 350 LX models with the following stock numbers:

907198, 907198-011, 907198-021, and 907198-031

200 VOLTS 230 VOLTS 460 VOLTS

1

L L L L L L

S-083 566-E

Or

Label found on 250 DX models with the following stock numbers:

907195, 907195-021 and, 907195-031

Label found on 350 LX models with the following stock numbers:

907199, 907199-021, and 907199-031

230 VOLTS 460 VOLTS 575 VOLTS

1

L L L L L L

S-010 587-D

Or

Label found on 250 DX models with stock number 907197

Label found on 350 LX models with stock number 907200

1

Y Disconnect and lockout/tag-

out input power before installing or moving jumper links.

Check input voltage available at site.

1 Jumper Link Label

Check label − only one label is on unit.

2 Jumper Links

Move jumper links to match input voltage.

Close and secure access door, or

go on to Section 4-21.

Tools Needed:

3/8 in

Ref. 803 585-A

OM-363 Page 29

4-21. Connecting Input Power

1

8

10

=GND/PE Earth Ground

7

9

L1

L2

6

2

4

1

5

3

Tools Needed:

3/8 in

4

6

Y Installation must meet all National and

Local Codes − have only qualified persons make this installation.

Y Disconnect and lockout/tagout input

power before connecting input conductors from unit.

Y Make input power connections to the

welding power source first.

Y Always connect green or green/yellow

conductor to supply grounding terminal first, and never to a line terminal.

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

1 Input Power Conductors (Customer

Supplied Cord)

Select size and length of conductors using

Section 4-19. Conductors must comply with

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

Welding Power Source Input Power Connections

2 Strain Relief

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

3 Machine Grounding Terminal

4 Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow grounding conductor to welding power source grounding terminal first.

5 Welding Power Source Line Terminals

6 Input Conductors L1 And L2

Connect input conductors L1 and L2 to welding power source line terminals.

Close and secure access door on welding power source.

Ref. 803 585-A

Disconnect Device Input Power Connections

7 Disconnect Device (switch shown in

OFF position)

8 Disconnect Device (Supply) Grounding

Terminal

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

9 Disconnect Device Line Terminals

Connect input conductors L1 and L2 to disconnect device line terminals.

10 Overcurrent Protection

Select type and size of overcurrent protection

using Section 4-19 (fused disconnect switch

shown).

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

OM-363 Page 30

SECTION 5 − OPERATION

5-1. Controls (350 LX Nameplates Shown)

A. For 200/230/460 Volts And Non CE Units

11

1 2 3 4 5 6

10

9

12

.

Top row of lights in upper left corner are

On for SMAW. Bottom row are On for

GTAW.

Green on nameplate indicates a TIG function,

Gray indicates a Stick function.

1 Process Control

See Section 5-3.

2 Amperage Control

See Section 5-4.

3 Output Control

See Section 5-5.

4 Start Mode Control

See Section 5-9.

5 Voltmeter And Ammeter

Voltmeter displays average voltage (to the nearest 0.1 V) at the weld output terminals.

Use meter to preset amperage. Meter displays average weld amperage output of unit to nearest ampere when welding.

NOTE: Meters are self-calibrating. No adjust-

7

8 ment available.

6 Amperage Adjustment

Control

Use control to adjust amperage, and preset amperage on ammeter. This control may be adjusted while welding.

For remote amperage control, front panel control setting is the maximum amperage available. For example: If front panel control is set to 200 amps, the range of the remote amperage control is 3 to 200 amps for 250 DX models, and 3 to 200 amps for 350 LX models.

For pulse welding, use Amperage Adjust control to select from 3-300 amps of peak amperage for 250 DX models, or 3−400 amps of peak amperage for 350 LX models (see Sec-

tion 5-12).

For spot welding, use Amperage Adjust control to select from 3-310 amps for 250 DX models, or 3−400 amps for 350 LX models

(see Section 5-16).

7 Output Selector Switch

See Section 5-2.

8 Power Switch

Use switch to turn unit Off and On.

9 Postflow Time Control

Use control to set length of time (0−50 seconds) gas flows after welding stops. It is important to set enough time to allow gas to flow until after the tungsten and weld puddle has cooled down.

Application:

Postflow is required to cool the tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance (approximately 1 second per 10 ampere of welding current).

10 Balance/DIG Control

See Section 5-10.

11 Pulser Controls (Optional on 250 DX model)

See Section 5-12.

12 Sequence Controls (Optional)

See Section 5-13.

217 264-A / 213 106-A

OM-363 Page 31

B. For CE Units

1 2 3 4 5 6

11

10

9

12

7

8

.

Top row of lights in upper left corner are

On for SMAW. Bottom row are On for

GTAW.

Green on nameplate indicates a TIG function,

Gray indicates a Stick function.

1 Process Control

See Section 5-3.

2 Amperage Control

See Section 5-4.

3 Output Control

See Section 5-5.

4 Start Mode Control

See Section 5-9.

5 Voltmeter And Ammeter

Voltmeter displays average voltage (to the nearest 0.1 V) at the weld output terminals.

Use meter to preset amperage. Meter displays average weld amperage output of unit to nearest ampere when welding.

NOTE: Meters are self-calibrating. No adjustment available.

6 Amperage Adjustment

Control

Use control to adjust amperage, and preset amperage on ammeter. This control may be adjusted while welding.

For remote amperage control, front panel control setting is the maximum amperage available. For example: If front panel control is set to 200 A, the range of the remote amperage control is 3 to 200 amps for 250 DX models, and 3 to 200 amps for 350 LX models..

For pulse welding, use Amperage Adjust control to select from 3-300 amps of peak amperage for 250 DX models, or 3−400 amps of peak amperage for 350 LX models (see Sec-

tion 5-12).

For spot welding, use Amperage Adjust control to select from 3-310 amps for 250 DX models, or 3−400 amps for 350 LX models

(see Section 5-16).

7 Output Selector Switch

See Section 5-2.

8 Power Switch

Use switch to turn unit Off and On.

9 Postflow Time Control

Use control to set length of time (0−50 seconds) gas flows after welding stops. It is important to set enough time to allow gas to flow until after the tungsten and weld puddle has cooled down.

Application:

Postflow is required to cool the tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance (approximately 1 second per 10 ampere of welding current).

10 Balance/DIG Control

See Section 5-10.

11 Pulser Controls (Optional on 250 DX model)

See Section 5-12.

12 Sequence Controls (Optional)

See Section 5-13.

215 460-A / 218 584-A

OM-363 Page 32

5-2. Output Selector Switch

1

5-3. Process Control

(CE Nameplate)

1

5-4. Amperage Control

(CE Nameplate)

1

1

1

1 Output Selector Switch

Y Do not use AC output in

damp areas, if movement is confined, or if there is danger of falling. Use AC output

ONLY if required for the welding process, and then use a remote control.

Y Do not change position of

switch while welding or while under load.

Use switch to select (DCEN) Direct

Current Electrode Negative, AC, or

(DCEP) Direct Current Electrode

Positive output.

NOTE: Changing position of Output Selector switch may change

Process control, Current control, and Start Mode control, and may require changing Output control settings to properly function with latest

Output Selector switch setting.

1 Process Control

Use control to select Shielded Metal Arc Welding (SMAW) or Gas

Tungsten Arc Welding (GTAW) process.

For SMAW, press button to toggle

LED to Stick position.

For GTAW, press button to toggle

LED to TIG position.

NOTE: Lit LED indicates selected mode.

When Output Selector switch position changes, LED may change position, based upon last selection.

Ref. 217 264-A / Ref. 215 460-A

1 Amperage Control

Use control to select front panel or remote amperage control.

For front panel amperage control, press button to toggle LED to Panel position.

For remote amperage control, press button to toggle LED to Re-

mote position (see Section 4-8).

NOTE: Lit LED indicates selected mode.

When Output Selector switch position changes, LED may change position, based upon last selection.

OM-363 Page 33

5-5. Output Control

Remote (Standard)Torch Trigger Operation

(CE Nameplate)

2

1

2

1

Current (A)

Preflow

Initial Amps

Push & Hold

Foot Or Finger

Remote Control

Remote (Standard)Torch Trigger Operation

Weld Amps

Final Slope

Release For

Maintained Switch

Final Amps

Postflow

Release Foot Or

Finger Remote

Control

1 Output Control

Y Weld output terminals are ener-

gized when power is On, and Output On LED is lit.

Use control to select front panel, trigger hold, or remote output control.

NOTE: Lit LED indicates selected mode.

For weld output, press button to toggle LED to On position.

2 Remote Trigger (Standard) Operation

For remote output control, press button to toggle LED to Remote position (see Sec-

tion 4-8).

Torch trigger operation is as shown.

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.

When Output Selector switch (see Section

5-2) position changes, Output control LED

will always switch to Remote.

OM-363 Page 34

3

Trigger Hold (2T)

(CE Nameplate)

3

Current (A)

2T Torch Trigger Operation

Weld Amps

Preflow

Initial Amps

Final Slope

Final Amps

Postflow

Push & Release Trigger

In Less Than 3/4 Sec.

Push & Release Trigger

In Less Than 3/4 Sec.

NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode (see previous page).

If arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 7-1).

3 Trigger Hold

For trigger hold operation, press button to toggle LED to Trigger Hold position.

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, as amperage is controlled by the welding power source.

Application: Trigger Hold (2T) can help to reduce operator fatigue when long extended welds are made.

OM-363 Page 35

5-6. 4T, 4T Momentary, And Mini Logoic Trigger Operation (Requires Optional Sequence

Controls)

4T Torch Trigger Operation

If unit is equipped with optional Sequence

Controls (see Section 5-13), 4T trigger

method is available.

4T 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.

Select 4T trigger method according to Sec-

tion 5-7.

Current (A)

Weld Amps

Final Slope

Initial Amps

Preflow

Final Amps

Postflow

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

If unit is equipped with optional Sequence

Controls (see Section 5-13), 4T Momen-

tary trigger method is available.

4T Momentary torch trigger operation is as shown.

While in 4T Momentary mode, once the operator toggles out of weld current and begins final slope, toggling again will break the arc and go to postflow.

4T Momentary Torch Trigger Operation

NOTE: When a remote switch is connected to the welding power source, only trigger input is functional. Amperage is controlled by the welding power source.

Application:

Use 4T Momentary trigger method when the functions of a remote current control are desired, but only a remote on/off control is available.

Select 4T Momentary trigger method ac-

cording to Section 5-7.

Current (A)

Weld Amps

Preflow

Initial Amps

Final Slope

Final Amps

Postflow

Push & Release

Trigger

Push & Release

Trigger

Push & Release

Trigger

Push & Release

Trigger

OM-363 Page 36

If unit is equipped with optional Sequence

Controls (see Section 5-13), Mini Logic op-

eration is available.

Torch trigger operation is as shown.

During Mini Logic welding operation, the weld amperage can be manually changed

Mini Logic Operation

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 amperage levels without either initial slope or final slope, gives the operator the opportunity to adjust filler metal without breaking the arc.

Select Mini Logic according to Section 5-7.

Weld Amps

Final Slope

Preflow

Initial Amps

Final Slope

Rate

Push & Hold

Trigger

Push & Hold

Trigger For More

Than 3/4 Sec.

Release Trigger

Push & Release

Trigger In Less

Than 3/4 Sec.

Initial Amps

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.

Postflow

OM-363 Page 37

5-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control

1 Output Control

2 Power Switch

To reconfigure Trigger Hold, turn Off power, push and hold Output control button and turn On power switch.

Hold button for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and meters display [SEL] [H−2].

Press Output control button to change functions. Active function will be displayed on amperage (bottom) meter.

3 Meter Displays

Meter displays for the different functions will be as shown.

Press torch trigger or turn power Off to save setting.

Proceed to Section 5-6 for 4T Opera-

tion.

Proceed to Section 5-6 for Mini Logic

operation.

Proceed to Section 5-6 for 4T Mo-

mentary operation.

NOTE: These features are only available when optional Sequencer is installed.

1

Front Panel

SEL

H−2

2

SEL

H-4E

SEL

H−4

= 4T

(See Section 5-6)

SEL

H4L

= Mini Logic

(See Section 5-6)

3

OM-363 Page 38

1

(CE Nameplate)

Front Panel

SEL

H−2

2

SEL

H-4E

SEL

H−4

= 4T

(See Section 5-6)

SEL

H4L

= Mini Logic

(See Section 5-6)

3

OM-363 Page 39

5-8. Selecting TIG Starting Characteristics Using Syncro-Startt Technology

1 4

E−

−2−

2

Use this function to select desired TIG starting characteristics.

1 Start Mode

2 Power Switch

3 Output Selector Switch

4 Meters

To select or change TIG starting characteristics, proceed as follows: turn Off power.

Place Output Selector switch in desired position (each position, DCEN, AC, or DCEP has three applicable start characteristics options). Push and hold Start Mode button and turn On power. Hold button for approximately

7 seconds (or until software version number_

_ _ _ _ _-_ clears meters).

The TIG LED and all four Start LEDs will light, and the meters will display [E−] [−2−], [AC] [−2−], or [EP] [−2−], depending on position of Polarity switch.

Press Start Mode button again to step through the three start characteristics choices.

Amperage (bottom) meter displays active choice 1= light start, 2=medium/normal start, 3=high/hot start.

3

Press torch trigger or turn Off power to save setting.

Application:

Select 1 (light/soft start) − when welding at low amperages on thin gauge material.

Select 2 (medium/normal start) − factory default setting used for most welding applications.

Select 3 (high/hot start) − when welding at high amperages on thick materials with a large diameter tungsten.

OM-363 Page 40

(CE Nameplate)

1

E−

−2−

4

3

2

OM-363 Page 41

5-9. Start Mode

(CE Nameplate)

1

Lift-Arct Start Method

2 3

“Touch”

1 − 2

Seconds

1

Do NOT Strike Like A Match!

1 Start Mode

For SMAW welding, press button to toggle

LED to Off position.

For GTAW welding, use control to select

Off for no HF, Lift-Arct, HF for arc starting only, or continuous HF.

Application:

When Off is selected, use the scratch method to start an arc for both the SMAW and GTAW processes.

When Lift-Arc is selected, start arc as follows:

2 TIG Electrode

3 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 sec-

onds, and slowly lift electrode. An arc will form when electrode is lifted.

Shielding gas begins to flow when electrode touches work piece.

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:

Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted, or to replace the scratch method.

When HF Start is selected, start arc as follows:

High frequency turns on to help start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc.

Application:

HF Start is used when the DCEN GTAW process is required.

When HF Continuous is selected, start arc as follows:

High frequency turns on when output is energized and remains on for duration of weld.

Application:

HF Continuous is used when the AC

GTAW process is required.

NOTE: Lit LED indicates selected mode.

When Output Selector switch position changes, LED may change position, based upon last selection.

NOTE: Some start methods may not be available for all processes.

OM-363 Page 42

5-10. Balance/DIG Control

1

Setting

Max Penetration

10

Max Cleaning

0

Balance Control Examples

Output Waveforms

50% Electrode

Positive

50% Electrode

Negative

32% Electrode

Positive

68% Electrode

Negative

55% Electrode

Positive

45% Electrode

Negative

(CE Nameplate)

1

Arc

1 Balance/DIG Control

Balance Control (AC GTAW):

Control changes the AC output square wave. Rotating the control towards 10 provides deeper penetration. Rotating the control towards

0 provides more cleaning action of the workpiece.

When the control is in the Balanced position, the wave shape provides equal penetration and cleaning action.

Application:

When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only a minimal amount, approximately a

0.10 in (2.5mm) of etched zone along the weld toes is required.

Set control to 3 and adjust as necessary. Joint configuration, set-up, process variables, and oxide thickness may affect setting.

NOTE: Arc rectification can occur when welding above 200 amps and/or while welding with helium gas. If this condition occurs, increasing the Balance control towards maximum penetration, may help to restabilize the arc.

DIG Control (AC And DC SMAW):

When set at 0, short-circuit amperage at low arc voltage is the same as normal welding amperage.

When setting is increased, shortcircuit amperage at low arc voltage increases. Set control at 2 and adjust as necessary. Joint configuration, set-up, and process variables may affect setting.

Application:

Control helps arc starting or making vertical, or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking while welding.

Ref. S-0795-A

OM-363 Page 43

5-11. Preflow Time Control

1

00.4

SEL

4

2

Use control to set length of time (0.2, 0.4, 0.6,

0.8, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0

seconds) gas flows before welding starts.

1 Process Control

2 Power Switch

3 Meters

To change preflow time, proceed as follows:

OM-363 Page 44

Turn power off. Push and hold Process Control button and turn On power. Hold button for approximately 7 seconds (or until software version number_ _ _ _ _ _-_ clears meters).

The TIG LED will light and the meters will display [o.4] [SEL]. The factory preflow default setting is 0.4 seconds. To change preflow time, press and release Process Control button until desired time is displayed on meters.

Application:

Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting.

1

(CE Nameplate)

00.4

SEL

4

2

OM-363 Page 45

5-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models)

1

1

Percent (%) Peak

Time Control Setting

Balanced

More Time

At Peak

Amperage

(50%)

More Time At

Background

Amperage

(20%)

(80%)

2

(CE Nameplate)

2

Bkg Amp

Peak Amp

5

Pulsed Output Waveforms

PPS

3

3

4

4

1 On/Off Control

Use control to turn pulse function

On and Off.

2 Background Amps

Use Background Amps control to set the low pulse of the weld amperage, which cools the weld puddle and affects overall heat input.

Background Amps is set as a percentage of peak amperage.

3 Pulse Frequency

Ranges from 0.25−10.0 pps

(pulses per second). Control is used to determine appearance of weld bead.

4 Peak Time

A range of 5−95% of each pulse cycle can be spent at the peak amperage level.

Peak amperage (3-310 amps for

250 DX models, and 3−400 amps for 350 LX models), is set with the

Amperage Adjustment control (see

Section 5-1). Peak amperage is the

highest welding amperage allowed to occur in the pulse cycle. Weld penetration varies directly with peak amperage.

5 Pulsed Output Waveforms

Example shows affect changing the Peak Time control has on the pulsed output waveform.

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, undercutting, and heat input. Controls can be adjusted while welding.

Pulsing can also be used for filler material addition technique training.

NOTE: Function is enabled, when

LED is lit.

OM-363 Page 46

5-13. Sequence Controls (Optional)

1

5

2

3

1 Initial Time Control

See Section 5-14.

2 Initial Amperage Control

See Section 5-14.

3 Final Slope Control

See Section 5-15.

4 Final Amperage Control

See Section 5-15.

5 Spot Time Control

See Section 5-16.

4

2

1

(CE Nameplate)

5

3

4

OM-363 Page 47

5-14. Initial Time Control And Initial Amperage Control

(CE Nameplate)

1

1

2

2

1 Initial Time Control

Indicator light is on when Initial

Time control function is active.

NOTE: Initial Sequence control function is inactive when Spot Time function is active.

Use control to select 0−15 seconds of start time.

2 Initial Amperage Control

Indicator Light is on when Initial Sequence control function is active.

NOTE: Initial Amperage control function is inactive when Spot Time function is active.

Use control to select a starting amperage (3−400 amps) that is different from the weld amperage. Note:

Initial Amperage can be used with or without a remote control (Initial

Amperage and Initial Time control settings will override a remote control device).

Application:

Initial Amperage can be used while

GTAW welding to assist in preheating cold material prior to depositing filler material, or to ensure a soft start. Initial Amperage can also be used for SMAW to ensure a more consistent arc strike.

NOTE: Function is enabled, when

LED is lit.

OM-363 Page 48

5-15. Final Slope Control And Final Amperage Control

(CE Nameplate)

1

2

1 Final Slope Control

Indicator light is on when Final Slope control function is active.

Note: Final Slope control function is inactive when Spot Time function is active.

Use control to reduce amperage over a set period of time (0−15 seconds) at the end of the weld cycle when NOT using a remote current control.

2 Final Amperage Control

Indicator light is on when Final Amperage control function is active.

Note: Final Amperage control function is inactive when Spot Time func-

tion is active (see Section 5-16).

Final amperage is the amperage to which weld amperage has sloped down to (0−100% of amperage set on

Amperage Adjust control).

Application:

Final Slope should be used while

GTAW welding materials that are crack sensitive, and/or the operator wants to eliminate the crater at the end of the weld.

Note: This applies if the operator is using an on/off only type control to start and stop the welding process.

Note: Do not use this function with a foot or finger amperage control.

NOTE: Function is enabled, when

LED is lit.

5-16. Spot Time Control

1

(CE Nameplate)

1

1 Spot Time Control

Indicator light is on when Spot Time function is active. When Spot Time function is active, Initial Time, Initial Amperage, Final Slope, and Final Amperage functions are inactive (see Section

5-13).

Used with the (GTAW) TIG Spot process, generally with a direct current electrode negative (DCEN) set-up.

Use control to select 0−15 seconds of spot time.

Use Amperage Adjust control (see Sec-

tion 5-1) to set amperage.

Application:

TIG spot welding is used for joining thinner materials that are in close contact with the fusion method. A good example would be joining coil ends.

NOTE: Function is enabled, when LED is lit.

OM-363 Page 49

5-17. Timer/Cycle Counter

1

2

(CE Nameplate)

1 2 3

4 5 6

3

1 2 3

4 5 6

4

1

2

1 Amperage Control

2 Output Control (Contactor)

To read timer/cycle counter, hold Amperage and Output (contactor) buttons while turning on power.

3 Timer Display

The hours and minutes are displayed on the volt and amp meters for the first five seconds, and are read as 1, 234 hours and 56 minutes.

4 Cycle Display

The cycles are displayed on the volt and amp meters for the next five seconds, and are read as 123, 456 cycles.

OM-363 Page 50

5-18. Resetting Unit To Factory Default Settings (All Models)

1

2

3

4

1 2

(CE Nameplate)

3 4

5

1 Process Control

2 Amperage Control

3 Output Control

4 Start Control

5

5 Power Switch

To reset all welding power source functions to original factory settings, turn power off.

Push and hold the Process, Amperage,

Output, and Start controls and turn On power. Hold switch pads for approximately 7 seconds (or until software version number

_ _ _ _ _ _-_clears meters).

OM-363 Page 51

SECTION 6 − MAINTENANCE

6-1. Routine Welding Power Source Maintenance

Y Disconnect power before maintaining.

3 Months

Replace

Unreadable

Labels

Repair Or

Replace

Cracked

Weld

Cables

Clean And

Tighten

Weld

Terminals

Adjust Spark

Gaps

14-Pin Cord

6 Months

Gas Hose

OR

Torch Cable

Blow Out Or Vacuum Inside,

During Heavy Service, Clean Monthly

Y Warranty is void if machine fails

due to contaminates inside.

6-2. Routine Cooler Maintenance

Y Disconnect power

before maintaining.

1 Month

Y Clean coolant strainer. Severe conditions may require more frequent cleaning (continuous use, high/low temperatures, dirty environment, etc.). Failure to properly clean

coolant strainer voids pump warranty.

6 Months

Replace

Cracked

Parts

Blow Out Heat

Exchanger Fins

Replace

Cracked

Hoses

Change Coolant

(If Using Water)

see Section 4-10

12 Months

Replace

Damaged Or

Unreadable

Labels

Oil

Motor

Change Coolant (If Using MILLER

Coolant) see Section 4-10

OM-363 Page 52

6-3. Circuit Breaker CB1

1

Y Turn off power before reset-

ting breaker.

1 Circuit Breaker CB1

If CB1 opens, high frequency and output to the 115 volts ac duplex receptacle stop. Press button to reset breaker.

Ref. 803 588-A

6-4. Adjusting Spark Gaps

803 592-A

1

3

4

2

Tools Needed:

0.012 in (0.305 mm)

3/8n

5/32 in

Y Turn Off welding power

source and disconnect and lockout/tagout input power before adjusting spark gaps.

Remove right side panel..

1 Tungsten End Of Point

Replace point if tungsten end disappears; do not clean or dress tungsten.

2 Spark Gap

Normal spark gap is 0.012 in (0.305

mm).

If adjustment is needed, proceed as follows:

3 Adjustment Screws

Loosen screws. Place gauge of proper thickness in spark gap.

4 Pressure Point

Apply slight pressure at point until gauge is held firmly in gap. Tighten screws. Adjust other gap.

Reinstall right side panel.

OM-363 Page 53

SECTION 7 − TROUBLESHOOTING

7-1. Voltmeter/Ammeter Help Displays

2 0

V

HLP

1

V

HLP

V

HLP

A

−−0

A

−−1

A

−−2

12

6

V

HLP

A

−−6

V

HLP

A

−12

7

V

HLP

A

−−7

13

V

HLP

A

−13

8

V

HLP

A

−−8

14

V

HLP

A

−17

9

3

V

HLP

A

−−3

V

HLP

A

−−9

15

V

HLP

A

−18

4

V

HLP

A

−−4

10

V

HLP

A

−10

16

V

HLP

A

−19

5

11

V

HLP

A

−−5

V

HLP

A

−11

.

All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.

0 Help 0 Display

Indicates a short in the thermal protection circuitry located on the transformer/stablizer of the unit.

1 Help1 Display

An SCR overcurrent or undercurrent condition has occurred. Turn power off and back on to correct condition.

2 Help 2 Display

Indicates an open in the thermal protection circuitry located on the transformer/stablizer of the unit.

3 Help 3 Display

Indicates the transformer/stablizer of the unit has overheated. The unit

has shut down to allow the fan to cool it (see Section 4-5). Operation

will continue when the unit has cooled.

4 Help 4 Display

Indicates an open in the thermal protection circuitry located on the rectifier assembly of the unit.

5 Help 5 Display

Rectifier assembly has overheated. The unit has shut down to allow

the fan to cool unit (see Section 4-5). Operation will continue when the

unit has cooled.

6 Help 6 Display

Not used.

7 Help 7 Display

Not used.

8 Help 8 Display

Not used.

9 Help 9 Display

Indicates a short in the thermal protection circuitry located on the rectifier assembly of the unit.

10 Help 10 Display

Indicates Remote Output control is activated. Release Remote Output control to clear help message.

11 Help 11 Display

Output Selector switch is not in correct position (see Section 5-2).

12 Help 12 Display

Indicates a non-allowable set-up of the front panel.

13 Help 13 - 16 Displays

Not used.

14 Help 17 Display

Malfunction in the thermal protection circuitry of the cooler.

15 Help 18 Display

Coolant system coolant has overheated. The unit has shut down to al-

low the coolant to cool (see Section 4-5). Operation will continue when

the coolant has cooled.

16 Help 19 Display

Indicates low coolant flow in the coolant system. The unit output has shut down and will not start again until the coolant flow level is corrected, and the power is turned off and back on.

OM-363 Page 54

7-2. Troubleshooting The Welding Power Source

NOTE: The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit.

There are no user serviceable parts inside unit.

Refer to Section 7-1 for any Help (HLP) message displayed on voltmeter/ammeter.

Trouble

No weld output; unit completely inoperative.

No weld output; unit on.

Unit provides only maximum or minimum weld output.

Erratic or improper weld output.

No control of weld output.

Remedy

Place line disconnect switch in On position (see Section 4-21).

Check and replace line fuse(s), if necessary (see Section 4-21).

Check for proper input power connections (see Section 4-21).

Check for proper jumper link position (see Section 4-20).

If using remote control, place Output control in Remote 14 position, and make sure remote control is connected to Remote 14 receptacle. If remote is not being used, place Output control in On position

(see Section 5-1).

Check, repair, or replace remote control.

Have Factory Authorized Service Agent check unit.

Make sure Amperage control is in proper position (see Section 5-1).

Have Factory Authorized Service Agent check unit.

Use proper size and type of weld cable (see Section 4-7).

Clean and tighten all weld connections.

Check position of Output Selector control (see Section Figure 5-1).

If using remote control, check position of Amperage Adjustment control (see Section 5-1).

If using remote control, place Output control in Remote 14 position, and make sure remote control is connected to Remote 14 receptacle. If remote is not being used, place Output control in On position

(see Section 5-1).

Make sure Amperage control is in proper position (see Section 5-1).

Reset circuit breaker CB1 (see Section 6-3).

No output from duplex receptacle RC2 and no high frequency.

Lack of high frequency; difficulty in starting GTAW arc.

Wandering arc − poor control of direction of arc.

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

Fan not operating.

Reset circuit breaker CB1 (see Section 6-3).

Select proper size tungsten (see Section 10).

Be sure torch cable is not close to any grounded metal.

Check cables and torch for cracked insulation or bad connections. Repair or replace.

Check spark gaps (see Section 6-4).

Reduce gas flow rate.

Select proper size tungsten (see Section 10).

Properly prepare tungsten (see Section 10).

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Properly prepare tungsten.

Check for water in torch, and repair torch if necessary.

Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to protect against overheating.

OM-363 Page 55

7-3. Troubleshooting The Welding Coolant System

Trouble

NOTE: The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit.

There are no user serviceable parts inside unit.

Refer to Section 7-1 for any Help (HLP) message displayed on voltmeter/ammeter.

Remedy

Coolant system does not work.

Check line fuses or circuit breaker, and replace or reset if necessary.

Decreased or no coolant flow.

Motor overheated. Unit starts running when motor has cooled.

Have Factory Authorized Service Agent check motor.

Add coolant (see Section 4-10).

Check for clogged hoses or coolant filter.

Disconnect return line and place it in a container of clean coolant. Prime unit according to Section

4-10. Flow rate should be a minimum of 1 liter (1.1 qt) per minute. If flow rate is still low, have Factory

Authorized Service Agent check unit.

Clean heat exchanger fins and blower assembly (see Section 6-2).

Decreased cooling ability; coolant too hot.

Foaming Coolant Check for cracked or loose hoses or loose cover on filter, and tighten or replace.

Check for loose cap or bad seal on filter assembly, and tighten or replace as necessary.

OM-363 Page 56

SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram For 250 DX Models

222 681-A

OM-363 Page 57

OM-363 Page 58

Figure 8-2. Circuit Diagram For 350 LX Models

222 683-A

SECTION 9 − HIGH FREQUENCY

9-1. 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

9-2. Incorrect Installation

13

50 ft

(15 m)

9

8

7

10

Weld Zone

11, 12

3

2

1

4 5 6

14

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

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-363 Page 59

9-3. Correct Installation

3

50 ft

(15 m)

Weld Zone

7

5

6

1

4

2

8

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

Locate high-frequency source at least 50 ft

(15 m) away from power and phone lines.

8 Grounding Rod

Consult the National Electrical Code for specifications.

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

Cover all windows and doorways with grounded copper screen of not more than

1/4 in (6.4 mm) mesh.

11 Overhead Door Track

Ground the track.

OM-363 Page 60

SECTION 10 − SELECTING AND PREPARING TUNGSTEN

ELECTRODE FOR DC OR AC WELDING

ac/dc_gtaw 2/2000

Y Whenever possible and practical, use DC weld output instead of AC weld output.

10-1. Selecting Tungsten Electrode (

Wear Clean gloves To Prevent Contamination Of Tungsten

)

Electrode Diameter

Amperage Range - Gas Type

- Polarity

(DCEN) − Argon

Direct Current Electrode Negative

AC − Argon

65% Electrode Negative

2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens

.040” (1 mm)

1/16” (1.6 mm)

3/32” (2.4 mm)

1/8” (3.2 mm)

25-85

50-160

135-235

250-400

Pure Tungsten (Green Band)

Pure Tungsten Not Recommended

For DCEN − Argon

20-80

50-150

130-250

225-360

.040” (1 mm)

1/16” (1.6 mm)

3/32” (2.4 mm)

1/8” (3.2 mm)

10-60

50-100

100-160

150-210

Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.

10-2. Preparing Tungsten Electrode For Welding

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.

A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines

Radial Grinding

Causes Wandering Arc

Wrong Tungsten Preparation

2

2-1/2 Times

Electrode Diameter

3

1

4

Ideal Tungsten Preparation − Stable Arc

1 Grinding Wheel

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 Tungsten Electrode

3 Flat

Diameter of this flat determines amperage capacity.

4 Straight Ground

Grind lengthwise, not radial.

B. Preparing Tungsten For Conventional AC Welding

1 − 1-1/2 Times

Electrode Diameter

1

2

1 Tungsten Electrode

2 Balled End

Ball end of tungsten by applying AC amperage recommended for a given electrode

diameter (see Section 10-1). Let ball on end

of the tungsten take its own shape.

OM-363 Page 61

70

104

89

104

19

28

18

SECTION 11 − PARTS LIST

.

Hardware is common and not available unless listed.

350 LX Model Illustrated

106

4

107

55

66

108

68

105

63

20

25

26

49

40

29

21

22

48

16

23

103

91

15

14

12

Figure 11-1. Main Assembly

OM-363 Page 62

350 LX Model Illustrated

104

83

11

2

108

109

87

41

54

42

96

95

97

35

38

37

39

3

5

7

8

46

6 13

10

9

78

80

75

58

1

82

72

97

78

76

73

34

104

53

33

59

44

43

64

65

104

52

803 804-C

OM-363 Page 63

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-1. Main Assembly

Quantity

Model

250

DX

350

LX

. . .

. . .

1

2

. . . . . . . . . . .

. . . . . . . . . .

. . . 3 . .

. . . 3 . .

. . . 3 . .

. . . 3 . .

. . . 3 . .

. . . 3 . .

T1/Z1

T1/Z1

T1/Z1

T1/Z1

.

. .

.

.

. . . . . . . . .

4

. .

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

211038

215656

212555

211041

215767

215389

. .

. .

. .

. .

. .

. .

BASE, ASSY

END CAP,

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

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

XFMR/STABILIZER ASSY, 200/230/460

XFMR/STABILIZER ASSY, 230/460/575

T1/Z1 219652 XFMR/STABILIZER ASSY, 220/400/440/520

XFMR/STABILIZER ASSY, 200/230/460

XFMR/STABILIZER ASSY, 230/460/575

4

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

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

1

1

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

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

T1/Z1

.

. 217801

. .

. .

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

XFMR/STABILIZER ASSY, 220/400/440/520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TH1 201443 THERMISTOR,NTC 10K OHM @ 25 DEG C 27.5IN LEAD

. . .

. . .

5

6

. . .

. . . 7 . .

. . . 8 . . .

TE1 . .

. . . . . . . . . .

212550

218175

. .

. .

. .

. .

PANEL, LEFT WINDTUNNEL (for non-TIGRUNNER models)

TERM ASSY, PRI 1PH 3V

C5, 6 111634 CAPACITOR ASSY,

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

213248 LUG, UNIV W/SCREW 2/0−14 WIRE .266STD

SR1

TH2

. .

. .

. . . . . . . . .

9

. .

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

212558

217069

218670

212559

218173

. .

. .

. .

. .

. .

. .

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

RECTIFIER, SCR MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMISTOR,NTC 30K OHM @ 25 DEG C 40IN LEAD

BRACKET, RECTIFIER RH

BRACKET, RECTIFIER LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RESISTOR, WW FXD 400 W 35 OHM W/MTG BKT

215390 SWITCH ASSY, POLARITY W/LEADS & HARDWARE (DX)

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

. . . 11 . . . .

. . . 12 . . . .

R3

S5

. .

. .

. . . 13 . . . . . . . . . +213105 PANEL, RIGHT WINDTUNNEL

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

. . . 15 . . . . . . . . . . .

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

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

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

. . .

. . .

16

18

. . .

. . . 22 . . .

PC1 . .

. . . . . . . . . .

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

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

. . . 21 . . . . . .

C14

215937

. .

. .

213114 FRONT PANEL ASSY,

117860

107983

143397

209877

183332

. .

. .

. .

. .

. .

. .

. .

SWITCH, TGL ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

BLANK, SNAP−IN NYL .187 MTG HOLE BLACK

BLANK, SNAP−IN NYL .500 MTG HOLE BLACK

BLANK, SNAP−IN NYL .312 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT CARD ASSY, CONTROL & INTERFACE W/PROGRAM

KNOB, POINTER .570 DIA X .125 ID W/SPRING CLIP

174991 KNOB, POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21

Figure 11-2

PANEL,LOWER DINSE CONN ASSY

. .

195778

209587

. .

. .

. .

. .

ACTUATOR PUSH BUTTON ASSY

CAPACITOR ASSY,

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

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

♦♦

195344 CIRCUIT CARD ASSY, PULSER, . . . 23 . . .

. . .

. . .

23

25

. . .

PC2

PC2 . .

. . . . . . . . . .

. . . 25 . . . . . . . . . .

195344

. .

. .

. .

CIRCUIT CARD ASSY, PULSER,

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

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

217264 NAMEPLATE, MILLER SYNCROWAVE DX (UPPER) WORD&SYMBOL 1

215460 NAMEPLATE, MILLER SYNCROWAVE DX (UPPER) CE WORDLESS 1

. . .

. . .

. . .

. . .

. . .

. . .

25

25

26

26

26

26

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

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

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

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

217263

213106

. .

. .

. .

. .

NAMEPLATE, MILLER SYNCROWAVE LX (UPPER) WORD&SYMBOL

212549 NAMEPLATE, MILLER SYNCROWAVE LX (UPPER) CE WORDLESS

NAMEPLATE, MILLER SYNCROWAVE DX (LOWER)

213107

. .

. . NAMEPLATE, MILLER SYNCROWAVE LX (LOWER)

218585 NAMEPLATE, MILLER SYNCROWAVE LX (LOWER) CE

.

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

218584 NAMEPLATE, MILLER SYNCROWAVE DX (LOWER) CE . . . . . . . . . . . . .

. . . . .

. . . . .

1

1

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

175952 PLASTIC, HANDLE SWITCH

169136 PIN, HANDLE

215685

. .

. .

. .

. . PANEL, GAS

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

1

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

1

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

. . . 33 . . . . . . . . . .

. . . 34 . . . . . . . . . .

. . . 35 . . . . . . . . . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

37

38

39

40

41

42

42

43

44

. . . . . . . . . .

. . FM1, 2

. . . .

. . .

1T

GS1

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . .

. .

. .

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

215691

212548

184058

187807

150783

220393

199312

215776

208408

. .

. .

. .

. .

. .

. .

. .

. .

. .

PANEL, GAS/WATER

PANEL, REAR

FAN, PLENUM

. .

204293 SUPPORT, LIFT EYE

212552

218280

. .

. .

. .

. .

SUPPORT, LIFT EYE

HINGE, CONT POLYOLEFIN

+215657 DOOR, ACCESS

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

BRACKET, MTG MOTOR FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLADE, FAN 9.000 5WG 39DEG .312 BORE CW PLSTC

MOTOR, FAN 230V 50/60HZ 1550 RPM .312 DIA SHAFT

BLOCK, TERMINAL FAST−ON,20 AMP,250 VOLT

VALVE, 24VDC 2WAY CUSTOM PORT 1/8 ORF W/FRICT

FTG, BRS BARBED FEM 1/4 TBG X .625−18 FLANGE MTG

217111 PLUG, PROTECTIVE

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

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

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

5

1

1

1

8

1

1

1

1

2

2

1

2

1

2

1

1

1

1

1

1

1

OM-363 Page 64

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-1. Main Assembly (continued)

. . . 46 . . . . . . . . . .

. . .

. . .

. . .

48

49

52

. . . . T4 . .

. . . . . . . . . .

. . . . . . . . .

. . . 53 . . . . . . . . . .

. . .

. . .

. . .

. . .

55

58

59

63

. . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

217553

215771

207560

211043 PANEL, SIDE

199479

. .

. .

. .

. .

. .

LABEL,GROUND/PROTECTIVE EARTH

COIL, HF COUPLING

INSULATOR, STANDOFF WITH STUD

. . . 54 . . . . . . . . . . . .

+211040 COVER, TOP

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

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

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

LABEL, MILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

026627 GASKET ,LIFTING EYE COVER

208294

010467

203990

. .

. .

. .

. .

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

CONNECTOR, FASTON MALE 4−PRONG

CONN, CLAMP CABLE 1.250

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

LABEL, WARNING GENERAL PRECAUTIONARY STATIC

127363 LABEL, WARNING ELECTRIC SHOCK CAN KILL . . . 64 . . . . . . . . . .

. . . 65 . . . . . . . . . . 218598

. .

. .

. . . 66 . . . . . . . . . . . .

♣ 204389 HOLDER, TORCH/CABLE

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

LABEL, WARNING ELECTRIC SHOCK AND INCORRECT INPUT P

201019 LABEL, WARNING ELECTRIC SHOCK EXCESS WEIGHT

. . . 68 . . . . . . . . .

. . . 70 . . . . . . . . . .

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

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

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

72

212557

. .

. . DRAWER, ASSY (includes)

. . . . DRAWER, PLASTIC

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

1

1

. . .

. . . 73

. . . .

. . . .

T3

G1

. .

. .

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

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

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

. . . 75 . . . . . .

. .

213111

213112

217255

. . . .

. . . .

DRAWER, FRAME

SLIDE, DRAWER

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

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

219927 XFMR, HIGH VOLTAGE 115V PRI 3600V SEC 34 MA W/TERM

2

199854

. .

. . SPARK GAP ASSY, (includes)

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

HOLDER, POINTS

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

1

. . . 76 . . . .

. . . .

. . .

R8

C3

199855

199856

196455

188067

. . . .

. . . .

. .

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

POINTS, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RESISTOR, WW FXD 100 W 200 OHM W/CLIPS

78 C11, 19 195552 CAPACITOR, POLYP MET FILM 20. UF 250 VAC 10%

80

82

. . . . R1 . . . .

C13 206878 CAPACITOR ASSY, . . .

83

. . . . .

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

. . . 87 . . . . . . . . . .

. . . 89 . . . . . . . . . . .

. .

215779 CAPACITOR, MICA .002 UF 10000 V PANEL MTG W/LEA

. .

220808 RESISTOR, WW FXD 100 W 50 OHM W/CLIPS

216081

. .

. . BRACKET, RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218170 HOSE, NPRN BRD NO 1 X .250 ID X 24.000

. . .

. . .

90

91

. . . . . . . . . .

. . .

. . . 95 . . . .

. . .

. . .

96

HD1 191941 TRANSDUCER, CURRENT

. . . . . . . . . .

. .

C2

. .

. .

. .

211039

192828

031668

. .

. .

. .

. .

. .

BEZEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, WARNING ELECTRICAL SHOCK ETC

108105 CLAMP, CAPACITOR

. .

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

CAPACITOR, ELCTLT 4000 UF 100 VDC

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

97 R2, 4 118459 RESISTOR, WW FXD 10 W 1K OHM

. . 103 . . PC3

♦♦

195345 . . CIRCUIT CARD ASSY, SEQUENCER

. .

. .

. .

104

105

106

. . . .

. . . .

Figure 11-4

. . TIGRUNNER RUNNING GEAR

Figure 11-3

. . ASSY, COOLER

. . . . . . . .

212556 . . PANEL, SIDE

211037 . . HOLDER, COOLANT FILLER . .

. .

107 . . . . . . . .

108 . . CR1 .

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

. . 109 . . . . . . . . .

059266 . . RELAY, ENCL 120VAC DPDT 10A/120VAC 8PIN

194744

222451

. .

. .

RFCS−14HD (FOOT CONTROL)

BRACKET, RELAY

Quantity

Model

250

DX

350

LX

1

1

1

1

1

1

1

1

1

1

2

1

2

1

1

4

1

1

4

1

1

1

2

1

1

1

2

1

1

1

1

1

2

2

1

2

2

1

1

1

1

2

1

1

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

Part of TIGRUNNER option.

♦♦

Field option only.

For TIGRUNNER models, the quantity is 1.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-363 Page 65

.

Hardware is common and not available unless listed.

10

11

12

3

10

11

12

5

14

13

9

1

8

14

9

2

13

8

Figure 11-2. Panel, Lower Dinse Connector Assembly

803 775-A

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

220 509

Figure 11-2. Panel, Lower Dinse Connector Assy (Figure 11-1 Item 21)

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

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

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

. . . 3 . . . . . . . . . . .

. . .

. . .

. . .

5

8

9

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

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

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

. . . 12 . . . . . . . . . .

. . . 13 . . . . . . . . . .

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

213109

218784

215778

. .

. .

. .

PANEL, LOWER DINSE CONN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, COMPONENT IDENTIFICATION CE WORDLESS . . . . . . . . . . . . . . .

211911 CONN, CIRC MS/CPC 14SKT SIZE 20 RCPT W/FILTERING

218174

. .

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

202553 RECEPTACLE, TWIST LOCK BRASS POWER (FEMALE)

185712

185713

185714

. . RECEPTACLE, W/LEADS & CIRCUIT BREAKER

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

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

185717 NUT, M20−1.5 1.00HEX .19H BRS LOCKING

186228

185718

. .

. .

. .

. .

. .

. .

. .

INSULATOR, BULKHEAD FRONT

INSULATOR, BULKHEAD REAR

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

WASHER, TOOTH 22MMID X 31.5MMOD 1.310−1MMT INTERN

O−RING, 0.739 ID X 0.070 H

O−RING, 0.989 ID X 0.070 H

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

. . . . . . . . .

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

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

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

2

2

1

2

1

1

1

1

2

2

2

2

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-363 Page 66

.

Hardware is common and not available unless listed.

16

20

13

20

18

5

10

20

20

2

20

3 20

7

20

6

19

4

3

21

20

17

20

20

15

1

9

8

5

20

14

Figure 11-3. Optional Cooler Assembly

803 779-C

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

212 544

Figure 11-3. Cooler Assy (Optional) Figure 11-1 Item 105)

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

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

. . . 3 . . . . . . . . . .

. . . 4 . . . . . . . . . .

. . .

. . .

5

6

. . . . . . . . . .

. . . . . . . . . .

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

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

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

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

. . . 13 . . . . . . . . . .

211036

215667

215669

221819

. .

. .

. .

. .

TANK,COOLANT

FILTER,

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

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

HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 2 IN

215688 . . FITTING,MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215675 . . HOSE, RUBBER BRAIDED 3/8 ID X 5/8 OD X 19 IN

215679 . . SWITCH, PRESSURE

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

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

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

FTG, HOSE BRS BARBED 45 DEGREE ELBOW M3/8 X 3/8 NPT

217173 . . RADIATOR, HEAT EXCHANGER

211042

211045

215683

. .

. .

. .

FAN, AC 230V BRUSHLESS

PUMP, COOLANT

HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 13-1/2 IN

215686 . . VALVE, CHECK BIDIRECTIONAL

. . . . . . . .

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

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

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

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

. . . . . . . . .

. . .

. . .

. . .

15

16

17

18

. . . . . . . . . .

. . . . . . . . . .

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

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

TH3 . . 217069 THERMISTOR,NTC 30K OHM @ 25 DEG C 40IN LEAD

. . . . . . . . . .

. . .

. . .

. . .

19

20

21

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

166608

220921 . . VALVE, CHECK BIDIRECTIONAL

215690 HOSE, RUBBER BRAIDED 3/8 ID X 1/2 OD X 3-1/2 IN

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

126978

176746

. .

. .

. .

. .

. .

. .

CAP, TANK SCREW−ON W/VENT

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

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

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

FTG, BRS BARBED M 3/8 TBG X 3/8 NPT

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

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

CLAMP, 1−EAR TYPE NOM DIM .656 X .275 WIDE

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

5523 FTG, HOSE BRS BARBED ELBOW M 3/8 TBG X 3/8 NPT

. .

215673 FITTING,

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

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

1

1

1

1

1

1

1

1

1

1

12

1

1

1

2

1

2

1

1

1

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-363 Page 67

.

Hardware is common and not available unless listed.

2

3

4

1

11

5

8

6

7

10

9

Figure 11-4. Optional Running Gear

Ref. 803 725-A

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 11-4. Running Gear (Optional) (Figure 11-1 Item 104)

. . .

. . .

. . .

. . .

1

2

3

4

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

218134

215928

168663

. .

. .

. .

. .

HANDLE, LH

602387 CHAIN

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

BOTTLE SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOOK SPRING SNAP

191158 BOTTLE TRAY

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

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

. . . 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121614 RETAINING RING . . .

. . .

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

. . .

. . .

. . .

6

7

9

10

11

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . .

163463

. .

. . WHEEL

191167 AXLE

168247

191163 CASTER MOUNTING BRACKET

218135

. .

. .

. .

. .

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

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

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

CASTER, SWIVEL

HANDLE, RH

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

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

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

2

1

1

2

3

2

1

1

2

1

1

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-363 Page 68

Notes

Notes

Warranty Questions?

Call

1-800-4-A-MILLER for your local

Miller distributor.

Your distributor also gives you ...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions?

Contact your distributor.

The expertise of the distributor and Miller is there to help you, every step of the way.

LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an

International distributor.

1.

5 Years Parts — 3 Years Labor

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2.

3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Sources (Unless Otherwise Stated)

* Water Coolant Systems (Integrated)

* Intellitig

* Maxstar 150

* Engine Driven Welding Generators

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

3.

1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Process Controllers

* Positioners and Controllers

* Automatic Motion Devices

* RFCS Foot Controls

* Induction Heating Power Sources and Coolers

* Water Coolant Systems (Non-Integrated)

* Flowgauge and Flowmeter Regulators (No Labor)

* HF Units

* Grids

* Maxstar 85, 140

* Spot Welders

* Load Banks

* Arc Stud Power Sources & Arc Stud Guns

* Racks

* Running Gear/Trailers

* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered under True

Blue ® for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

4.

6 Months — Batteries

5.

90 Days — Parts

* MIG Guns/TIG Torches

Effective January 1, 2004

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

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

* Induction Heating Coils and Blankets

* APT & SAF Model Plasma Cutting Torches

* Remote Controls

* Accessory Kits

* Replacement Parts (No labor)

* Spoolmate Spoolguns

* Canvas Covers

Miller’s True Blue

®

Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat,

Trailblazer, and Legend models.)

2.

Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3.

Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND

PERSONS TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Miller authorized service facility as determined by

Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR

ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION

OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

miller_warr 6/04

Owner’s Record

Please complete and retain with your personal records.

Model Name

Purchase Date

Distributor

Address

City

State

Serial/Style Number

(Date which equipment was delivered to original customer.)

Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Contact the Delivering Carrier to:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information and Parts)

Circuit Diagrams

Welding Process Handbooks

To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller

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

©

2004 Miller Electric Mfg. Co. 10/04

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

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

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