Miller Electric Syncrowave 500, LK280110L Owner's manual

Miller Electric Syncrowave 500, LK280110L Owner's manual
2009−06
Processes
TIG (GTAW) Welding
ENGLISH
OM-225 389N
Arc Welding Power Source
Syncrowave 200
R
File: TIG (GTAW)
Visit our website at
www.MillerWelds.com
ESPAÑOL
Description
FRANÇAIS
Stick (SMAW) Welding
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification 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 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
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 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Included with Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Duty Cycle Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. DC Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. AC Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. 115 Volts AC Duplex Receptacle And Supplementary Protector CB1 . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. Typical TIG Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14. Typical Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16. Connecting Input Power In 208-230 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-17. Connecting Input Power In 460/575 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Ammeter, Voltmeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Amperage/Purge Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Pulse Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Factory Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Postflow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Selecting Syncro Start Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Pulser Peak And Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Software Number/Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING . . . . . . . . . . . . . .
7-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . .
7-2. Preparing Tungsten Electrode For Welding With Phase Control Machines . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 8 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
33
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som _2007−04
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
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.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
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 Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
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.
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 Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
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 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 Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
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 in inverter-type
welding power sources after removal of input
power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-225 389 Page 1
ENGLISH
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
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 local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand 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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
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 an approved welding helmet fitted with a proper shade of filter lenses 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 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.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT 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.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
NOISE can damage hearing.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
Noise from some processes or equipment can
damage hearing.
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 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 Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
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 Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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, sparks, and fire
hazards.
OM-225 389 Page 2
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, physical damage, 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 Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
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.
FALLING UNIT can cause injury.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
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.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine replacement parts from the
manufacturer.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
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.
FLYING SPARKS can cause injury.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
D
D
D
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-225 389 Page 3
ENGLISH
1-3. Additional Symbols For Installation, Operation, And Maintenance
1-4. California Proposition 65 Warnings
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.)
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:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 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, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd 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, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.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 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them, or using a
cable cover.
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.
2. Arrange cables to one side and away from the operator.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-225 389 Page 4
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 Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
2-1. Included with Your Unit
1
8
2
3
5
7
4
5
6
7
8
9
4
6
9
3
12 ft (3.7 m) Work Cable
With Clamp And
Quick-Connect
WP1712SFDI 150 Amp
TIG Torch with 12 ft (3.7 m)
Cable And Quick-Connect
Electrode Holder and
Quick-Connect
Gas Hose
Gas Regulator
Cable/Torch Hanger
Foot Pedal Holder
8 ft (2.4 m) Primary Cord
Without Plug (208/230
Models Only)
RFCS-14 Foot Control with
20 ft (6 m) Cable
. Some assembly is required.
2
For options and accessories see
back of book or contact your distributor.
1
804 464-B
2-2. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
1
3
OR
2
Location And Airflow
Position unit so air can circulate.
For information about sources of
high-frequency see Section 6.
For carts and caster kits see back
of book or contact your distributor.
3
!
18 in. (460 mm)
18 in. (460 mm)
Line Disconnect Device
Locate unit near correct input power supply.
18 in.
(460 mm)
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
18 in. (460 mm)
OM-225 389 Page 5
ENGLISH
SECTION 2 − INSTALLATION
2-3. Dimensions And Weights
B
C
Dimensions
D
Height
29-3/4 in. (756 mm)
Width
17-1/4 in. (438 mm)
Length
23-1/2 in. (597 mm)
A
19-1/16 in. (484 mm)
B
1 in. (25 mm)
C
14-3/4 in. (375 mm)
D
1 in. (25 mm)
E
1/2 in. (13 mm)
F
4 Holes 7/16 in. dia (11 mm)
A
F
Front
E
804 239-B
Weight
228-1/2 lbs (104 kg)
244-1/2 lbs (111 kg)*
* TIGRunner models
2-4. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the front of the machine. Use the rating labels to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
2-5. Specifications
Model
208-230
460
575
Mode
Rated Output at 40%
Duty Cycle
Welding
Rated Input,
60 HZ, Single-Phase
KVA
KW
Amperage Range
Max. OCV
DC TIG
150 Amps at 16 Volts
208−230 V - 45 A - (2)*
10.2 - (0.50)*
4.3 - (0.3)*
5−200
80
DC Stick
150 Amps at 26 Volts
208-230 V - 47 A - (2)*
10.8 - (0.50)*
5.8 - (0.3)*
5−200
80
AC TIG**
150 Amps at 16 Volts
208-230 V - 54 A - (2)*
12.3 - (0.50)*
4.5 - (0.3)*
5−200
80
AC Stick
150 Amps at 26 Volts
208-230 V - 54 A - (2)*
12.4 - (0.50)*
6 - (0.3)*
5−200
80
DC TIG
150 Amps at 16 Volts
460 V - 22 A - (1)*
10.2 - (0.50)*
4.3 - (0.3)*
5−200
80
DC Stick
150 Amps at 26 Volts
460 V - 25 A - (1)*
10.8 - (0.50)*
5.8 - (0.3)*
5−200
80
AC TIG**
150 Amps at 16 Volts
460 V - 28 A - (1)*
12.3 - (0.50)*
4.5 - (0.3)*
5−200
80
AC Stick
150 Amps at 26 Volts
460 V - 28 A - (1)*
12.4 - (0.50)*
6 - (0.3)*
5−200
80
DC TIG
150 Amps at 16 Volts
575 V - 19 A - (.5)*
10.2 - (0.50)*
4.3 - (0.3)*
5−200
80
DC Stick
150 Amps at 26 Volts
575 V - 20 A - (.5)*
10.8 - (0.50)*
5.8 - (0.3)*
5−200
80
AC TIG**
150 Amps at 16 Volts
575 V - 22 A - (.5)*
12.3 - (0.50)*
4.5 - (0.3)*
5−200
80
AC Stick
150 Amps at 26 Volts
575 V - 22 A - (.5)*
12.4 - (0.50)*
6 - (0.3)*
5−200
80
* () While idling.
** Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position.
OM-225 389 Page 6
Duty cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
40% Duty Cycle at 150 A AC/DC
4 Minutes Welding
6 Minutes Resting
226 798-A
2-7. DC Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of welding
power source. Curves of other settings fall between curves shown.
70
60
50
40
DC Stick Min (Max DIG)
30
20
DC Stick Max (Max DIG)
10
0
DC TIG Min
0
50
DC TIG Max
100
150
AMPS
200
250
300
ssb1.1 10/91 − 226 800-A
OM-225 389 Page 7
ENGLISH
2-6. Duty Cycle Chart
2-8. AC Volt-Ampere Curves
70
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of welding
power source. Curves of other settings fall between curves shown.
AC TIG Min
60
50
AC Stick Max
40
30
AC Stick Min
20
10
AC TIG Max
0
0
50
100
AMPS
OM-225 389 Page 8
150
200
ssb1.1 10/91 − 226 799-A
!
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
!
!
Turn off power before
connecting to weld
output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
10 − 100% Duty Cycle
Do not use worn, damaged, undersized, or
poorly spliced cables.
Electrode
Work
804 234-C
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.
S-0007-D
2-10. Remote 14 Receptacle
Socket*
A
B
K
J
I
H
C L N
D M
G
E F
A
Socket Information
A
15 volts DC.
B
Contact closure to A completes 15 volts DC contactor control
circuit.
C
Command reference; 0 to +10 volts DC output to remote control.
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from remote control.
K
Chassis common.
*The remaining sockets are not used.
OM-225 389 Page 9
ENGLISH
2-9. Weld Output Terminals And Selecting Cable Sizes
2-11. 115 Volts AC Duplex Receptacle And Supplementary Protector CB1
!
Turn Off power before connecting to receptacle or resetting protector.
1
Supplementary Protector CB1
If CB1 opens, high frequency and
output to the 115 volts ac duplex receptacle stop. Press button to reset
protector.
2
115 V 15 Amp AC Receptacle
Provides 115 volts, 15 amps of ac
power for equipment such as grinders, drills, coolers, etc.. Receptacle
is protected from overload by supplementary protector CB1.
2
1
804 267-C
2-12. Shielding Gas Connections
4
Tools Needed:
5/8, 1-1/8 in
5
!
Turn Off power before connecting to receptacle.
1
Gas Valve In Fitting
Fitting has
threads.
3
5/8-18
right-hand
Located on rear of unit.
2
Gas Valve Out Fitting
Gas connection is integrated into
the Electrode weld output terminal
by means of a flow-through type
connector.
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 gas hose to gas in fitting.
5
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour).
1
2
804 234-C / 804 235-C
OM-225 389 Page 10
Turn off power before making connections.
1
Remote Foot Control
A customer supplied remote fingertip control may also be used.
6
2
3
5
7
!
Torch
Work Clamp
Connect remote control, torch, and
work clamp to receptacles as
shown.
4
Cylinder
Chain or secure cylinder to running
gear, wall, or other stationary
support.
5
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
6
Regulator/Flow Gauge
Install so face is vertical.
Tools Needed:
4
5/8, 1-1/8 in
7
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour) (9.4 L/min).
After activating remote control, 0.2
seconds of gas preflow will begin.
Preflow Application:
Preflow is used to purge the immediate weld area of atmosphere.
Preflow also aids in consistent arc
starting. Preflow is preset and is not
adjustable.
Post Flow Application:
Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or
weld are dark in appearance (see
Section 3-8).
2
1
3
OM-225 389 Page 11
ENGLISH
2-13. Typical TIG Connections
2-14. Typical Stick Connections
!
Turn off power before making connections.
1
2
Electrode Holder
Work Clamp
Connect electrode holder and work
clamp to receptacles as shown.
1
2
2-15. Electrical Service Guide
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
. All values calculated at 40% duty cycle.
. Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in table. If actual input voltage is outside of this range, damage
to unit may occur.
50/60 Hz Single Phase
208-230
460
575
54
27
22
Time-Delay 2
60
30
25
Normal Operating 3
80
40
30
8
12
14
147 (45)
249 (76)
256 (78)
8
12
14
Input Voltage
Input Amperes At Rated Output
Max Recommended Standard Fuse or circuit breaker Rating In Amperes 1
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5”. See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps 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.
Reference: 2005 National Electrical Code (NEC)
OM-225 389 Page 12
1
!
Installation must meet all National
and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input power before connecting input
conductors from unit.
=GND/PE Earth Ground
5
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
1
Black And White Input Conductor
(L1 And L2)
Green Or Green/Yellow Grounding
Conductor
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Disconnect Device Grounding
Terminal
Disconnect Device Line Terminals
7
4
2
6
L1
L2
1
3
4
5
2
6
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
3
Connect input conductors L1 and L2 to
disconnect device line terminals.
7
Over-Current Protection
Select type and size of over-current
protection using Section 2-15 (fused disconnect switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
804 234-C / Ref. 803 766-B
‘
2-17. Connecting Input Power In 460/575 Volt Models
A. Placing Jumper Links
!
1
2
Disconnect and lockout/tagout input power before
installing or moving jumper
links.
Check input voltage available at
site.
Remove cover and left side panel.
1
2
Jumper Link Label
Jumper Links
Move jumper links to match input
voltage.
Install left side panel and cover, or
go on to Section B.
Tools Needed:
3/8 in
Ref. 804 470-B
OM-225 389 Page 13
ENGLISH
2-16. Connecting Input Power In 208-230 Volt Models
B. Connecting Input Power In 460/575 Volt Models
8
=GND/PE Earth Ground
10
7
9
L1
L2
5
6
6
4
4
2
1
3
Tools Needed:
3/8 in
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit.
!
Make input power connections to the
welding power source first.
!
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 2-15. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
OM-225 389 Page 14
804 470-B
Welding Power Source Input Power Connections
Disconnect Device Input Power Connections
2
7
Strain Relief
Route conductors (cord) through strain relief
and tighten screws.
3
Machine Grounding Terminal
4
Green Or Green/Yellow Grounding
Conductor
8
Disconnect Device (switch shown in
OFF position)
Disconnect Device (Supply) Grounding
Terminal
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
Connect green or green/yellow grounding
conductor to welding power source grounding
terminal first.
9
5
Welding Power Source Line Terminals
10 Overcurrent Protection
6
Input Conductors L1 And L2
Select type and size of overcurrent protection
using Section 2-15 (fused disconnect switch
shown).
Connect input conductors L1 and L2 to welding power source line terminals.
Install panels and wrapper on welding power
source.
Disconnect Device Line Terminals
Connect input conductors L1 and L2 to
disconnect device line terminals.
Close and secure door on line disconnect device. Remove lockout/tagout device, and
place switch in the On position.
ENGLISH
SECTION 3 − OPERATION
3-1. Controls
6
5
4
0000
7
0000
3
8
2
9
1
228 528-A / 242 738-A
1
Output Selector Switch (Polarity)
2
!
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.
See Section 3-5.
6
3
See Section 3-2.
Do not change position of switch while
welding or while under load.
4
!
Use switch to select Direct Current Electrode
Negative (DCEN), AC, or Direct Current Electrode Positive (DCEP) output without changing
weld output cable connections.
Pulse Push Button Control
Main Amps Push Button
(Amperage/Purge Control)
See Section 3-3.
Encoder Adjustment Control
See Section 3-2.
7
Voltmeter And Parameter Adjust
Adjust Push Button Control
See Section 3-6.
8
Process Push Button Control
Use control in conjunction with applicable front
panel function switch to set values for that function.
See Section 3-4.
5
Use switch to turn unit On and Off.
Ammeter And Parameter Adjust
9
Power Switch
OM-225 389 Page 15
3-2. Ammeter, Voltmeter And Parameter Display
1
2
Ammeter
Displays actual amperage while
welding. Meter also displays preset
parameters for any of the following
units of measure when they are active: amperage, time, percentage or
frequency.
1
2
Voltmeter
Displays output or open-circuit voltage while output is on. Meter also
displays preset parameters.
3-3. Amperage/Purge Control
1
3
2
3
See Section 3-7 for Amperage
range.
2
200 A
Main Amps Push Button
(Amperage Control)
Encoder Adjustment Control
Ammeter
Amperage Control:
Press and release Main Amps push
button, and turn Encoder control to
set weld amperage. Weld amperage setting is also peak amperage
when Pulser function is active (see
Section 3-5).
1
Purge Control:
Press and hold Main Amps push
button to activate the gas purge.
Purge time can be adjusted from 1
to 50 seconds by turning Encoder
control while holding the Amps button. Preset purge time is 0 seconds.
3-4. Process Control
1
Process Control
Press Process button until desired
process LED is illuminated:
1
TIG - When selected, an HF (noncontact) arc starting method is activated. Weld output is not available
until a remote control is activated.
This method can be used with either
AC or DC TIG welding. Make connections according to Section 2-13.
!
Weld output terminals are energized when power is on, and
Output On LED is lit.
Stick (SMAW) - When Stick is selected, weld output is on, terminals
are energized, and output LED is lit.
This method can be used with either
AC or DC Stick welding. Make connections according to Section 2-14.
OM-225 389 Page 16
1
2
PPS
10.0
3
1
2
3
4
Ammeter
Voltmeter
Encoder Adjustment Control
Pulse Control
Pulsing is available only while using
the TIG process, it cannot be selected if the Stick process (see Section 3-4) is active. Controls can be
adjusted while welding.
Press Pulse push button to activate
pulser function.
ON - When illuminated, this LED
indicates the pulser is on.
4
Turn Encoder to set pulses per second. See Section 3-7 for Pulse parameters. The selected pulse value
is displayed on the ammeter, and
[PPS] is displayed on the voltmeter
as long as the pulse function is active.
Press Pulse control button to turn
pulse function off.
Press Main Amps or Adjust control
button to exit pulse control screen
and leave pulser activated.
Application:
Pulsed TIG welding involves
switching the weld output between
a high or peak amperage, and a low
or background amperage at a controlled rate of pulses per second.
Pulsing the weld output from a higher peak amperage, to a lower background amperage, lowers the average welding amperage, which can
reduce heat input and improve weld
puddle control.
Set the number of pulses per second based on the application. Pulsing rates of 1 to 2 pps can improve
the timing and amount of filler metal
that are added to the weld puddle,
improving weld bead consistency.
Filler metal should be dipped, or
added to the weld puddle when the
output pulses to the high, or peak
amperage.
Fast pulsing rates can improve the
bead appearance of welds made
without filler, or allow filler to be continuously added to the weld puddle
without any dipping action. The
pulse rate should be adjusted along
with travel speed to obtain desired
weld bead appearance.
OM-225 389 Page 17
ENGLISH
3-5. Pulse Control
3-6. Balance/DIG Control
1
2
3
4
Ammeter
Voltmeter
Encoder Adjustment Control
Adjust Control
Select desired process, AC TIG or DC Stick
(see Section 3-4).
2
AC TIG
Display
DC Stick
Display
Press Adjust push button to turn Balance/
DIG function and LED on.
1
BAL
7
DIG
30%
3
If AC TIG is selected, turn encoder control to
select appropriate balance value (see Section 3-7). The selected value is displayed on
the ammeter, and [BAL] is displayed on the
voltmeter.
Balance changes the AC squarewave output.
Set control to 7 and adjust as necessary (see
Balance Control Examples). Set at a higher
value to decrease the arc cleaning (or etching) zone and increase penetration, or set at
a lower value to increase arc cleaning action
of the workpiece.
Application:
Joint configuration, set-up, process variables, and oxide thickness may affect setting.
!
4
AC weld output is preferred for aluminum due
to the oxide cleaning action it provides. AC
balance controls the amount of cleaning action which should be adjusted according to
how heavy or thick the surface oxides are.
Adjust ac balance to the highest setting that
provides approximately 0.10 in (2.5 mm) of
etching zone along the weld toes, while maintaining a clear, shiny weld puddle.
Balance Control Examples
Output Waveforms
Setting
Typical Starting Point
7
BAL
More Penetration
BAL
Do not use AC output in damp areas,
if movement is confined, or if there is
a danger of falling . Use AC output
only if required for the welding
process.
10
43% Electrode
Positive
57% Electrode
Negative
40% Electrode
Positive
60% Electrode
Negative
Arc
AC balance should be decreased if a distinct
etching zone is not visible near the weld toes,
or if the weld puddle appears to have dark,
pepper-like spots on the surface.
If DC Stick is selected, turn encoder control
to select the appropriate amount of Dig (see
Section 3-7). The selected value is displayed
on the ammeter, and [DIG] is displayed on the
voltmeter.
When set at 0, the DIG current will provide no
additional short-circuit amperage at low arc
voltage. Increasing the DIG percentage increases the short circuit amperage at a low
arc voltage to help start and maintain an arc
and prevent the electrode from sticking to the
workpiece.
Application:
Increase the DIG percentage to reduce or
prevent the electrode from sticking to the
workpiece.
• For cellulose electrodes (6010, 6011), use
a DIG setting of 50 to 80%.
• For low hydrogen electrodes (7018), use a
DIG setting of 20 to 35%.
• For other electrodes, set DIG high enough
to prevent electrode sticking.
• Setting DIG too high could result in burn
thru and unwanted digging due to excessive short circuit current.
OM-225 389 Page 18
Parameter
Default
Range And Resolution
PROCESS
TIG HF
TIG HF, STICK
AC
150 A
5 − 200 Amps
DC
150 A
5 − 200 Amps
PULSER
Off
ON / OFF
PPS
10 PPS
0.1−15 PPS
PEAK t
50%
20 − 80 Percent
BKGND A
50%
5 − 95 Percent
POSTFLOW
Auto
5 - 50 Amps: 5 Seconds
A MAIN / PEAK
51 - 200 Amps: Adds 1 Second Per 10 Amps
Manual:
1 -25 Seconds
DIG
30%
0 − 100 Percent
BALANCE
7
1−10
AC
Med
Soft/Med/Hot
DC
Med
Soft/Med/Hot
TIG HF Syncro-Startt Settings
OM-225 389 Page 19
ENGLISH
3-7. Factory-Set Parameter Defaults And Range And Resolution
3-8. Postflow Control
Postflow time is automatically controlled. Auto-postflow provides a
minimum of five seconds of postflow for anything less than 50 amps
of weld current, and an additional
one second of postflow for each
additional ten amps of weld current.
3
2
0000
0000
1
2
3
Power Switch
Process Control
Encoder Adjust Control
To override auto-postflow and set a
specific postflow time, press and
hold Process push button while
turning on power. Hold button for
approximately 7 seconds. Voltmeter will display POST, and ammeter
will display AUTO. Turn encoder to set
desired time in seconds. Postflow
settings effects AC and DC TIG,
and is not polarity specific. Press
torch trigger or turn off power to
save settings.
Application:
1
OM-225 389 Page 20
Auto-postflow time is optimally set
based on weld amperage. This
amount of auto-postflow time provides adequate shielding with no
manual adjustment. The use of
auto-postflow at low amperages
avoids excessive postflow times
and a waste of shielding gas. See
Section
3-7
for
postflow
parameters.
1
2
3
4
3
0000
0000
Power Switch
Main Amps Control
Volt And Ammeters
Process Selector Switch
To change TIG HF Syncro starting characteristics, turn Off power, place Output
Selector switch in desired position,
DCEN, DCEP or AC. Each position has
three start characteristics options. Push
and hold Main Amps button and turn on
power. Hold button for approximately 7
seconds.
2
Meters will display [AC] [MED] or [DCEN] [MED],
or [DCEP] [MED], depending on position of
Output Selector switch
Turn Encoder to step through the three
start characteristics choices. Ammeter
displays active choice: soft start, medium start, or hot start.
Change polarity (see Section 3-1) to set
values for each TIG output. Each setting
is polarity specific.
Press torch trigger or turn off power to
save settings.
1
Application:
Soft start - use for thin gauge material
and
small
diameter
tungstens
(.040−1/16 in)
Medium start - factory-set default, used
for most welding applications with 1/16,
3/32 and 1/8 in. tungstens.
Hot start - use for thick materials with a
large diameter tungsten (1/8−5/32 in.).
4
OM-225 389 Page 21
ENGLISH
3-9. Selecting Syncro Start Characteristics
3-10. Pulser Peak And Background
1
2
Push and hold Pulser button and turn
on power. Hold button for approximately 7 seconds.
4
3
4
3
0000
Power Switch
Pulse Control
0000
2
Encoder Control
Volt And Ammeter
Press Pulse button to cycle parameters (see Section 3-7 for parameter
ranges).
PPS (Pulses Per Second or Pulse
Frequency) is used to determine appearance of weld bead (See Section
3-5).
PEAK t [PKT] [50%]- The percentage
of each pulse cycle that can be spent
at the peak amperage level.
BKGND A [BKA] [50%] - (Background
Amps) - Use Background Amps 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.
1
Turn encoder to select appropriate
value for active pulse parameter. Value selected is shown on the ammeter.
5
Pulsed Output Waveforms
Example shows affect changing the
Peak Time control has on the pulsed
output waveform.
Peak amperage is set using the Main
Amps push button control (see Section 3-3), or with a remote control.
Peak amperage is the highest welding amperage allowed to occur in the
pulse cycle. Weld penetration varies
directly with peak amperage.
5
Percent (%) Peak
Time Control Setting
Balanced
(50%)
More Time
At Peak
Amperage
(80%)
More Time
At
Background
Amperage
OM-225 389 Page 22
Application:
Pulsed Output Waveforms
PPS
Bkg Amp
Peak Amp
Pulsed TIG welding involves switching the weld output between a high or
peak amperage, and a low or background amperage at a controlled rate
(see Section 3-5). 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.
(20%)
ENGLISH
3-11. Timer/Cycle Counter
4
3
0000
0000
2
1234 Hour
59 MINS
5
1234
5678
1
1
Power Switch
2
Process Control
3
Pulse Control
To read timer/cycle counter, press and hold
the Process and Pulse buttons, and turn
power on.
4
Timer Display
The hours are displayed for five seconds,
and then the minutes are displayed for five
seconds.
5 Cycle Display
The cycles are displayed for the next five
seconds, and are read as 12,345,678
cycles.
OM-225 389 Page 23
3-12. Software Number/Revision
4
3
0000
161
221
0000
2
5
REV.A
1
1
2
3
Power Switch
Process Control
Adjust Control
To read software number/revision, press
OM-225 389 Page 24
and hold the Process and Adjust buttons,
and turn power on.
4
Software Number Display
The software number is displayed for five
seconds.
5
Revision Display
The revision is displayed for the next five
seconds.
4-1. Routine Maintenance
!
Disconnect power before maintaining.
. Maintain more often during severe conditions.
3 Months
Replace o-ring in Electrode/Gas
Output receptacle if cracked.
Replace unreadable labels.
Repair or replace cracked weld
cable.
Repair or replace cracked gas
hose.
6 Months
Blow out or vacuum inside.
Or
4-2. Adjusting Spark Gaps
2
1
4
4
Tools Needed:
3
3/8 in
804 236-C /Ref. 803 592-C
!
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 0.008 in. (0.203 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 to 12 in/
lbs torque. Adjust other gap.
Reinstall right side panel.
OM-225 389 Page 25
ENGLISH
SECTION 4 − MAINTENANCE AND TROUBLESHOOTING
4-3. Voltmeter/Ammeter Help Displays
. All directions are in reference to the
tory Authorized Service Agent.
front of the unit. All circuitry referred to
is located inside the unit.
1 Help 0 Display
Indicates a short in the thermal protection
circuitry located on the transformer of the
unit. If this display is shown, contact a Factory Authorized Service Agent.
2 Help1 Display
An SCR overcurrent condition has occurred. Turn power off and back on to correct condition. If problem continues, contact a Factory Authorized Service Agent.
3 Help2 Display
Indicates an open in the thermal protection
circuitry located on the transformer of the
unit. If this display is shown, contact a Fac1
3
4
OVER TEMP XFMR
Indicates the transformer of the unit has
overheated. The unit has shut down to allow the fan to cool it (see Section 2-6). Operation will continue when the unit has
cooled.
5
Help 4 Display
Indicates an open in the thermal protection
circuitry located on the rectifier assembly of
the unit. If this display is shown, contact a
Factory Authorized Service Agent.
6
OVER TEMP RECT
Indicates the rectifier assembly of the unit
has overheated. The unit has shut down to
allow the fan to cool it (see Section 2-6). Op-
V
A
HELP
0
2
eration will continue when the unit has
cooled.
7 Help 9 Display
Indicates a short in the thermal protection
circuitry located on the rectifier assembly of
the unit. If this display is shown, contact a
Factory Authorized Service Agent.
8 REL RMT
Indicates Remote Output control is activated. Release Remote Output control to
clear help message.
9 POL ERR
Indicates Output Selector switch is not in
correct position (see Section 3-1).
10 NOT VALID
Indicates a non-allowable set-up on the
front panel.
V
A
HELP
1
4
V
A
V
A
HELP
2
OVER
TEMP
XFMR
5
V
A
HELP
4
6
V
A
OVER
TEMP
RECT
8
7
9
V
A
V
A
HELP
9
REL
RMT
V
A
V
A
POL
ERR
NOT
VALID
OM-225 389 Page 26
10
}
Toggles Every
Two Seconds
}
Toggles Every
Two Seconds
.
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 4-3 for any Help (HLP) message displayed on voltmeter/ammeter.
Trouble
No weld output; unit completely
inoperative.
Remedy
Place machine power switch in On position (see Section 3-1).
Place line disconnect switch in On position (see Section 2-16).
Check and replace line fuse(s), if necessary (see Section 2-16).
Check for proper input power connections (see Section 2-16).
No weld output; unit on.
Check, repair, or replace remote control.
Have Factory Authorized Service Agent check unit.
Unit provides only maximum or
minimum weld output.
Make sure Amperage control is in proper position (see Section 3-1).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 2-9).
Have Factory Authorized Service Agent check unit.
Clean and tighten all weld connections.
Lay weld cables out straight, do not leave weld cables coiled.
Check position of Output Selector control (see Section Figure 3-1).
If using remote control, check position of Amperage Adjustment control (see Section 3-1).
No control of weld output.
Make sure Amperage control is in proper position (see Section 3-1).
Lack of high frequency; difficulty in
starting GTAW arc.
Select proper size tungsten (see Section 7-1).
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 4-2).
Wandering arc − poor control of
direction of arc.
Reduce gas flow rate (see Section 2-13).
Select proper size tungsten (see Section 7-1).
Properly prepare tungsten (see Section 7-2).
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time (see Section 3-8).
Check and tighten all gas fittings.
Properly prepare tungsten (see Section 7-2).
Fan not operating.
Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.
No weld output; fan does not run.
Place line disconnect switch in On position (see Section 2-16).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 2-16).
Check for proper input power connections (see Section 2-16).
No weld output; fan on.
Be sure Output Selector switch is not set between positions (see Section 3-1).
Tighten remote control connection to Remote 14 receptacle (see Section 2-10).
Check remote control (see remote control Owner’s Manual).
Unit overheated. Allow unit to cool (see Section 2-6).
Fan not operating; weld output
available.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
OM-225 389 Page 27
ENGLISH
4-4. Troubleshooting
SECTION 5 − ELECTRICAL DIAGRAM
231 276-B
Figure 5-1. Circuit Diagram For 208−230 Volt Models
OM-225 389 Page 28
ENGLISH
Figure 5-2. Circuit Diagram For 460/575 Volt Models
231 299-B
OM-225 389 Page 29
SECTION 6 − HIGH FREQUENCY
6-1. Welding Processes Requiring High Frequency
1
1
High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
Work
TIG
high_freq 7/05 − S-0693
6-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
OM-225 389 Page 30
5
6
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
ENGLISH
6-3. Correct Installation
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
9
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
8
11 Overhead Door Track
Grounding Rod
Consult the National Electrical Code for
specifications.
Ground the track.
OM-225 389 Page 31
SECTION 7 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING
gtaw_Phase_2007−04
!
Whenever possible and practical, use DC weld output instead of AC weld output.
7-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens
.040” (1 mm)
25-85
20-80
1/16” (1.6 mm)
50-160
50-150
3/32” (2.4 mm)
135-235
130-250
250-400
225-360
1/8” (3.2 mm)
Pure Tungsten (Green Band)
.040” (1 mm)
Pure Tungsten Not Recommended
10-60
1/16” (1.6 mm)
For DCEN − Argon
50-100
3/32” (2.4 mm)
100-160
1/8” (3.2 mm)
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.
7-2. Preparing Tungsten Electrode For Welding With Phase Control Machines
!
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
2-1/2 Times
Electrode Diameter
Radial Grinding
Causes Wandering Arc
1
3
2
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
A 2% ceriated tungsten is recommended.
4
Wrong Tungsten Preparation
Ideal Tungsten Preparation − Stable Arc
3
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
B. Preparing Tungsten For AC Welding
1
Tungsten Electrode
A pure tungsten is recommended..
1 − 1-1/2 Times
Electrode Diameter
1
OM-225 389 Page 32
2
2
Balled End
Ball end of tungsten by applying AC amperage recommended for a given electrode
diameter (see Section 7-1). Let ball on end of
the tungsten take its own shape.
2007−04
8-1. Positioning The Torch
!
Grinding the tungsten electrode produces dust and flying sparks which can cause
injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using cerium or
lanthanum based tungsten
instead of thoriated. Thorium dust contains low-level
radioactive material. Properly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
1
Workpiece
3
2
4
90°
1
Make sure workpiece is clean
before welding.
2
Work Clamp
Place as close to the weld as
possible.
10−15°
4
5
6
10−25°
3
4
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare
according to Section 7.
tungsten
Guidelines:
5
6
1/16 in
3/16 in
Bottom View Of Gas Cup
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
The tungsten extension should be
no greater than the inside diameter
of the gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
OM-225 389 Page 33
ENGLISH
SECTION 8 − GUIDELINES FOR TIG WELDING (GTAW)
8-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
Tilt torch
Remove rod
15°
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
OM-225 389 Page 34
ENGLISH
8-3. Positioning Torch Tungsten For Various Weld Joints
90°
Butt Weld And Stringer Bead
70°
20°
20°
“T” Joint
70°
10°
20°
40°
Lap Joint
70°
20°
30°
90°
Corner Joint
70°
20°
ST-162 003 / S-0792
OM-225 389 Page 35
SECTION 9 − STICK WELDING (SMAW) GUIDELINES
9-1.
Stick Welding Procedure
!
Weld current starts when
electrode touches workpiece.
!
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.
Equipment Needed:
Tools Needed:
. Always wear appropriate per1
Constant Current
Welding Power Source
sonal protective clothing.
Workpiece
Make sure workpiece is clean before welding.
2
3
Work Clamp
Electrode
A small diameter electrode requires less current than a large
one. Follow electrode manufacturer’s instructions when setting weld
amperage (see Section 9-2).
4
5
6
5
4
Insulated Electrode Holder
Electrode Holder Position
Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
2
7
3
Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
6
1
7
stick 2008−05 − ST-151 593
OM-225 389 Page 36
6013
7014
7018
7024
Ni-Cl
308L
ENGLISH
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
EP
6011
AC
PENETRATION
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
DC*
6010
ELECTRODE
450
400
350
300
250
200
150
POSITION
6010
&
6011
100
50
DIAMETER
AMPERAGE
RANGE
Electrode and Amperage Selection Chart
ELECTRODE
9-2.
MIN. PREP, ROUGH
HIGH SPATTER
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
9-3.
Striking an Arc
1
2
3
Electrode
Workpiece
Arc
Scratch Technique
1
2
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out, electrode was lifted too
high. If electrode sticks to workpiece, use a quick twist to free it.
Tapping Technique
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free
it.
3
1
2
3
S-0049 / S-0050
OM-225 389 Page 37
9-4.
Positioning Electrode Holder
1
2
End View Of Work Angle
Side View Of Electrode Angle
1
10°-30°
90°
2
90°
Groove Welds
10°-30°
45°
1
2
45°
Fillet Welds
S-0060
9-5.
Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
2
3
5
1
S-0053-A
9-6.
Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals being welded.
2
3
4
5
4
5
No Overlap
Good Penetration into Base
Metal
1
S-0052-B
OM-225 389 Page 38
Conditions That Affect Weld Bead Shape
. Weld bead shape is affected
by
electrode angle,
arc
length, travel speed, and
thickness of base metal.
Angle Too Small
Correct Angle
10° - 30°
Angle Too Large
Electrode Angle
Drag
Spatter
Arc Length
Too Short
Normal
Too Long
Slow
Normal
Fast
Travel Speed
S-0061
9-8.
Electrode Movement During Welding
. Normally,
2
1
1
2
3
3
a single stringer
bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple
stringer beads work better.
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side to Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a
wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of
electrode.
S-0054-A
OM-225 389 Page 39
ENGLISH
9-7.
9-9.
Butt Joints
1
Tack Welds
Prevent edges of joint from drawing together ahead of electrode by
tack welding the materials in position before final weld.
1
2
2
3
1/16 in.
(1.6 mm)
Square Groove Weld
Good for materials up to 3/16 in. (5
mm) thick.
Single V-Groove Weld
Good for materials 3/16 − 3/4 in.
(5-19 mm) thick. Cut bevel with
oxyacetylene or plasma cutting
equipment. Remove scale from
material after cutting. A grinder can
also be used to prepare bevels.
30°
Create 30 degree angle of bevel on
materials in V-groove welding.
4
4
3
Double V-Groove Weld
Good for materials thicker than
3/16 in. (5 mm).
S-0062
9-10. Lap Joint
1
2
Electrode
Single-Layer Fillet Weld
Move electrode in circular motion.
3
30°
Or Less
30°
Or Less
1
1
Multi-Layer Fillet Weld
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
3
2
S-0063 / S-0064
9-11. Tee Joint
1
2
Electrode
Fillet Weld
Keep arc short and move at definite rate of speed. Hold electrode
as shown to provide fusion into the
corner. Square edge of the weld
surface.
For maximum strength weld both
sides of upright section.
1
2
45°
Or
Less
1
2
3
3
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
9-8. Remove slag before making
another weld pass.
S-0060 / S-0058-A / S-0061
OM-225 389 Page 40
1
2
3
Vise
Weld Joint
Hammer
Strike weld joint in direction shown.
A good weld bends over but does
not break.
3
3
2 To 3 in.
(51-76 mm)
1/4 in.
(6.4 mm)
2
1
2 To 3 in.
(51-76 mm)
2
1
S-0057-B
9-13. Troubleshooting
Porosity − small cavities or holes resulting from gas pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding
weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
OM-225 389 Page 41
ENGLISH
9-12. Weld Test
Lack Of Penetration − shallow fusion between weld metal and base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
Possible Causes
Corrective Actions
Unsteady hand.
Use two hands. Practice technique.
Distortion − contraction of weld metal during welding that forces base metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Corrective Actions
Excessive heat input.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-225 389 Page 42
ENGLISH
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-225 389 Page 43
SECTION 10 − PARTS LIST
1
2
5
6
7
4
3
17
10
9
8
13
50
51
49
55
12
59
18
58
52
11
57
61
22
20
16
69
23
25
24
15
63
71
39
48
26
40
42
65
43
45
25
64
38
60
44
30
68
46
37
47
41
28
66
67
29
31
19
62
27
33
32
34
Figure 10-1. Main Assembly
21
14
53
56
70
OM-225 389 Page 44
. Hardware is common and
not available unless listed.
805 461-A
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly
. . . 1 . . . . . . . . . . 223 302
. . . 2 . . . . . . . . . . 222 779
. . . 3 . . . . . . . . . . 169 136
. . . 4 . . . . . . . . . . 175 952
. . . 5 . . . . . . . . . . 195 778
. . . 6 . . . . . . . . . . 222 782
. . . 7 . . . . . . . . . . 242 733
. . . 8 . . . . . . . . . . 183 332
. . . 9 . . . . . . . . . . 224 498
. . . 10 . . . . . . . . . . 190 512
. . . 11 . . . . S5 . . 224 594
. . . 12 . . . . S1 . . 128755
. . . 13 . . C5,C6 . 223 952
. . . 14 . . . PC1 . . 231 996
. . . 15 . . T1/Z1 . 223 299
. . . 15 . . T1/Z1 . 226 884
. . . 16 . . . . . . . . . . 224 442
. . . 17 . . . . . . . . . . 199 479
. . . 18 . . . . . . . . . . 244 786
. . . 19 . . . . . . . . . . 242 736
. . . 20 . . . . . . . . . . 203 990
. . . 21 . . . . . . . . . . 223 301
. . . 22 . . . . . . . . . +242 737
. . . 23 . . . . . . . . . . 213 073
. . . 24 . . . . . . . . . . 242 732
. . . 25 . . R1,R4 . 220 808
. . . 26 . . . . . . . . . . 213 072
. . . 27 . . . . . . . . . . 223 300
. . . 28 . . . . . . . . . . 242 735
. . . 29 . . . GS . . 238 805
. . . 30 . . . . . . . . . +242 734
. . . 31 . . . . . . . . . . 604 102
. . . 32 . . . . . . . . . . 240 997
. . . 33 . . . . . . . . . . 137 761
. . . 34 . . . . . . . . . . 185 759
. . . 37 . . . . R2 . . 189 132
. . . 38 . . . . C1 . . 191 944
. . . 39 . . . HD1 . . 191 941
. . . 40 . . . . . . . . . . 224 496
. . . 41 . . . . . . . . . +242 731
. . . 42 . . . . . . . . . . 224 460
. . . 43 . . . C18 . . 195 552
. . . 44 . . . . C3 . . 239 528
. . . 45 . . . . T3 . . 219 927
. . . 46 . . . . G1 . . 221 738
. . . . . . . . . . . . . . . . 221735
. . . . . . . . . . . . . . . . 221734
. . . . . . . . . . . . . . . . 221736
. . . . . . . . . . . . . . . . 221737
. . . 47 . . . . R8 . . 211 261
. . . 48 . . . . . . . . . . 242 749
. . . 49 . . . C14 . . 206 878
. . . 50 . . . . T4 . . 222 793
. . . 51 . . . . . . . . . . 207 560
. . . 52 . . . . . . . . . . 242 738
. . . 53 . . . . . . . . . . 218 170
. . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FRONT, BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLASTIC, HANDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ACTUATOR PUSH BUTTON ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NAMEPLATE, SYNCROWAVE 200 UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, POINTER .570 DIA X .125 ID W/SPRING CLIP . . . . . . . . . . . . . . . . . .
. . BUSHING, FLG 375−32X423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND−OFF,NO 6−32 X .640 LG .250 HEX AL FEM . . . . . . . . . . . . . . . . . . . .
. . SWITCH ASSY, POLARITY W/LEADS & HARDWARE . . . . . . . . . . . . . . . . .
. . SWITCH, TGL DPST 40A 600VAC SCR TERM WIDE TGL . . . . . . . . . . . . . .
. . CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, CONTROL & INTERFACE W/PROGRAM . . . . . . . .
. . XFMR/STABILIZER ASSY (208−230 VOLT MODELS) . . . . . . . . . . . . . . . . . . .
. . XFMR/STABILIZER ASSY (460/575 VOLT MODELS) . . . . . . . . . . . . . . . . . . .
. . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, MILLER 9.562 X 4.000 HORIZONTAL . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, SIDELH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, SIDE RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, WARNING GENERAL PRECAUTIONARY STATIC . . . . . . . . . . . . . .
. . HANGER,CABLE/TORCH (PART OF ACCESSORY KIT) . . . . . . . . . . . . . . . .
. . COVER, TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEAL, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLENUM, MID PLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW FXD 100 W 50 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . . . . .
. . FAN, MUFFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, FOOT PEDAL (PART OF ACCESSORY KIT) . . . . . . . . . . . . . . . . .
. . BAFFLE, FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE, 24VDC 2WAY,125 PSI CUSTOM PORT.054 ORF W/FRICTION . . .
. . PANEL, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONN, CLAMP CABLE 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CORD SET, 250V 8GA 3/C 8’ ST JKT (208−230 VOLT MODELS ONLY) . . .
. . NUT, 750 NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, WARNING ELECTRIC SHOCK & INPUT POWER . . . . . . . . . . . . . . .
. . RESISTOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, POLYP MET FILM 10. UF 250 VAC 10% . . . . . . . . . . . . . . . . . .
. . TRANSDUCER, CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER ASSY, (FIGURE 10-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, WARNING ELECTRICAL SHOCK SPARK GAP(ENG/FR) . . . . . . . .
. . CAPACITOR, POLYP MET FILM 20. UF 250 VAC 10% . . . . . . . . . . . . . . . . . .
. . CAPACITOR, MICA .002 UF 10000 V PANEL MTG W/LEADS . . . . . . . . . . .
. . XFMR, HIGH VOLTAGE 115V PRI 3600V SEC 34 MA W/TERM . . . . . . . . . .
. . SPARK GAP ASSY, HF (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BASE, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . HOLDER, POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . POINTS, SPARK GAP (DUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . POINTS, SPARK GAP (SINGLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW FXD 100 W 200 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . . . .
. . BASE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COIL, COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, STAND−OFF WITH STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NAMEPLATE, SYNCROWAVE 200 LOWER
.........................
. . HOSE, NPRN BRD NO 1 X .250 ID X 25.000 . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
1
4
1
1
1
1
5
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
1
1
1
1
2
1
1
OM-225 389 Page 45
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly (continued)
. . . 55 . . . C13 . . 209 587 . . CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . 223 981 . . PANEL, LOWER DINSE CONN ASSY (FIGURE10-2) . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . TE1 . . 224 127 . . TERM ASSY, PRI 1PH 3V(460/575 VOLT MODELS)
.................. 1
. . . 58 . . . . . . . . . . 228 010 . . LABEL, RATING CARD SYN 200 208−230V . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . 228 011 . . LABEL, RATING CARD SYN 200 460/575V
......................... 1
. . . 59 . . . . . . . . . . 228 718 . . CORE, FERRITE BOX CLAMPON .350” BLK
...................... 1
. . . 60 . . . TH2 . . 206 327 . . THERMISTOR, NTC 30K OHM @ 25 DEG C 27 IN LEAD . . . . . . . . . . . . . . . 1
. . . 61 . . . TH1 . . 201 443 . . THERMISTOR, NTC 10K OHM @ 25 DEG C 27.50IN LEAD . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 141 162 . . HOUSING PLUG+PINS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . . . . . . . . . . . . . . 224 452 . . KIT, ACCESSORY (INCLUDES) (ALSO INCLUDES ITEMS 21 AND 27)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (SEE FIGURE 10-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 209 282 . . . . . . . . RFCS-14, FOOT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 188 860 . . . . . . . . WORK CABLE, W/CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 234 263 . . . . . . . . REGULATOR/FLOWMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 176 840 . . . . . . . . HOLDER, ELECTRODE W/CABLE & DINSE CONNECTOR . . . . . . . . 1
. . . . . . . . . . . . . . . . 198 317 . . . . . . . . HOSE, GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . WP1712MFDI50 . . . . . . TORCH PKG, 150A, 12FT, AIR, W/ 50MM FLOW CONNECTOR . . . 1
. . . 62 . . . . . . . . r242 742 . . . BRACKET, TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . r242 740 . . . TRAY, BOTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . r242 741 . . . AXLE, RUNNING GEAR .750 DIA X 23.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . r235 506 . . . SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . r209 869 . . . WHEEL, POLY−OLEFIN 10 IN DIAX 2.000WIDEX.750 . . . . . . . . . . . . . . . . . 2
. . . 67 . . . . . . . . r602 250 . . . WASHER, FLAT .812IDX1.469ODX.134T STL PLD ANSI.750 . . . . . . . . . . . 2
. . . 68 . . . . . . . . r121 614 . . . RING, RTNG EXT .750 SHAFT X .085 THK E STYLE PLD . . . . . . . . . . . . . 2
. . . 69 . . . . . . . . r242 730 . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . r008 999 . . . CASTER, SWVL 4.00 IN POLYOLEFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 71 . . . . . . . . r228 542 . . . LABEL,WARNING CYLINDER MAY EXPLODE IF DAMAGED(ENG/FR/SP)1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
rOptional
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-225 389 Page 46
13
. Hardware is common and
not available unless listed.
3
4
5
6
3
5
2
4
7
8
1
9
7
10
8
12
9
803 775-B
11
Figure 10-2. Panel, Lower Dinse Connector Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
223 981
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
213 109
218 174
185 717
229 338
185 713
224 529
185 718
185 712
186 228
202 811
202 553
218 784
185 706
..
..
..
..
..
..
..
..
..
..
..
..
..
Quantity
10-2. Panel, Lower Dinse Connector Assy (Figure 10-1 Item 56)
PANEL, LOWER DINSE CONN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, W/LEADS & CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . .
NUT, M20−1.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, DOMED LOAD .812 ID X 1.450 OD X .070 THK . . . . . . . . . . . . . .
INSULATOR, BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN, CIRC MS/CPC 14SKT SIZE 20 RCPT W/FILTERING . . . . . . . . . . . . .
O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE,TWIST LOCK ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, TWIST LOCK BRASS POWER (FEMALE) . . . . . . . . . . . . . . .
LABEL, COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LNUT, M12−1.0 .62HEX .24H BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
2
1
2
2
2
1
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-225 389 Page 47
1
. Hardware is common and
not available unless listed.
3
2
4
804 399-A
Figure 10-3. Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
224 496
...
...
...
...
1
2
3
4
..........
..........
..........
..........
206 984
206 327
224 488
208 384
..
..
..
..
Quantity
Figure 10-3. Rectifier Assembly (Figure 10-1 Item 40)
HEAT SINK,RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR,NTC 30K OHM @ 25 DEG C 27IN LEAD . . . . . . . . . . . . . . . . .
BUS BAR,RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THYRISTOR,SCR MODULE 136A 400V DUAL . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
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-225 389 Page 48
Notes
Notes
Effective January 1, 2009
(Equipment with a serial number preface of LK or newer)
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.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
* Accessory (Kits)
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
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 delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Fume Extractors
* 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.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
6 Months — Batteries
90 Days — Parts
* MIG Guns and Subarc (SAW) Guns
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.
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.
3.
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 2009−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
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.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2009 Miller Electric Mfg. Co.
2009−01
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