Miller MF302369D Owner's manual

Miller MF302369D Owner's manual
OM-265 270D
2015−07
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
STH 270
CE
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your 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 catalog sheets.
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 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Specifications For STH 270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Weld Output Connections . . . . . . . . . . . . . . .
4-6. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Stick DCEP (Direct Current Electrode Positive)Weld Output Connections . . . . . . . . . . . . . . . . . . . . . .
4-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Connecting To 3-Phase Engine Generator w/400 Volt Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Preparing Unit For Stick (SMAW) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Preparing Unit For TIG (GTAW) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Trigger Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Sequence Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Pulser Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. HF Current Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. TIG Lift-Arc Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Resetting Unit To Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Lift-Arc Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
7
8
8
8
8
9
9
10
10
11
11
11
12
12
13
13
14
15
16
16
17
18
19
19
20
21
22
23
23
24
24
25
25
25
26
27
TABLE OF CONTENTS
SECTION 8 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . . .
9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
28
28
28
29
30
30
30
31
33
40
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the prod­
uct(s) identified in this declaration conform to the essential requirements and provisions of the stat­
ed Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
STH 270
059016024
Council Directives:
·2006/95/EC Low Voltage
·2004/108/EC Electromagnetic Compatibility
·2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
·IEC 60974-1:2012 Arc Welding Equipment – Part 1: Welding Power Sources
·IEC 60974-3:2013 Arc Welding Equipment – Part 3: Arc striking and stabilizing devices
·IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic Compatibility Requirements
EU Signatory:
July 1st, 2015
___________________________________________________________________________________
Massimigliano Lavarini
Date of Declaration
ITW WELDING ITALY PRODUCTION MANAGER
956 172 239
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
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.
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, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter 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 burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-265 270 Page 1
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. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
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 from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
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 containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (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.
D Do not use welder to thaw frozen pipes.
OM-265 270 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing 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.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
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 compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
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.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed 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 compressed 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. Do
not stand in front of or behind the regulator when opening the 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.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
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 and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
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
D Sparks can cause fires — keep flammables away.
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.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
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.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
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-265 270 Page 3
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.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, 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, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, 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 (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,
Quincy, MA 02269 (phone: 1-800-344-3555, 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 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-265 270 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
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.
SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
OM-265 270 Page 5
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
Notes
OM-265 270 Page 6
2-2. Miscellaneous Symbols And Definitions
A
I
V
Amperage
High Temperature
Output/On
Hot Start
Gas Tungsten Arc
Welding (GTAW)
On
Shielded Metal
Arc Welding
(SMAW)
Percent
Positive
Volts
U1
IP
I1max
I1eff
U0
Primary Voltage
Degree Of
Protection
Rated Maximum
Supply Current
Maximum
Effective Supply
Current
Rated No Load
Voltage (Average)
Negative
Disturbance
Alternating
Current
Postflow
Hertz
Slope Down Time
Arc Force
Set-Up
Rated Welding
Current
Panel
Duty Cycle
Background
Current
Lift-Arc Start
(GTAW)
Direct Current
Slope Up Time
Protective Earth
(Ground)
Line Connection
Final Current
Voltage Input
3 Phase Static
Frequency
Converter-Transfo
rmer-Rectifier
Hz
Voltage Output
Off
Remote
Process
I2
X
U2
Conventional
Load Voltage
Notes
OM-265 270 Page 7
SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the bottom 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.
3-2. Specifications For STH 270
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-8 and 4-9 for information on connecting input power.
Input Power
Rated Welding Output
Three Phase
AC 50/60 Hz
Voltage
400 Volts Stick
100%
40%
180A
270 A
27.2V
30.8 V
Max.
Open
Circuit
Voltage
Amperage/
Voltage
Range DC
KVA/KW @
Duty Cycle
Dimensions
(in.)
Weight
50 V
5−270 A
20 − 30.8 V
11.4 KVA/
10.3 KW @
40 % DC
L: 568 mm
(22.4 in.)
W: 219 mm
(8.6 in.)
H: 345 mm
(13.6 in.)
Net: 24 Kg
(52.9 lb)
Ship: 26Kg
(57.3 lb)
7.9 KVA/
7.0 KW @
100% DC
400 Volts TIG
180A
17.2V
270 A
20.8 V
50 V
5−270 A
10 − 20.8 V
7.7 KVA/
6.7 KW @
40% DC
4.8 KVA/
4.0 KW @
100% DC
3-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
Output Amperes
300
If unit overheats, output stops and
cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before
welding.
STICK/TIG
250
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
200
150
100
50
10
50
100
270 Amps @ 40% Duty Cycle
180 Amps @ 100% Duty Cycle
4 Minutes Welding
6 Minutes Resting
Overheating
A or V
0
15
Minutes
OM-265 270 Page 8
OR
Reduce Duty Cycle
3-4. Volt-Ampere Curves
DC Voltage (V)
Volt-ampere curves show minimum and maximum voltage
and amperage output capabilities of welding power source.
Curves of other settings fall between curves shown.
54
52
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
0
10 20 30 40 50 60 70 80 90 100110 120 130140150 160170180190200 210220230240250 260270280
DC Amperage (A)
3-5. Environmental Specifications
A. IP Rating
IP Rating
Operating Temperature Range
IP23S
This equipment is designed for outdoor use. It
may be stored, but is not intended to be used
for welding outside during precipitation unless
sheltered.
-10 to 40 °C (14 to 104°F)
B. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
C. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment does not comply with IEC 61000−3−12. If it is connected to a public low voltage system, it is the responsibility of the installer
or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment can be connected.
IEC/TS 61000-3-4 can be used to guide parties concerned by the installation of arc welding equipment with an input current greater than 16 A
in a low voltage network.
ce-emc 2 2014-07
OM-265 270 Page 9
SECTION 4 − INSTALLATION
4-1. Selecting a Location
1
Movement
Location And Airflow
!
Do not move or operate unit
where it could tip.
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
Shoulder Strap
2
Use strap to lift unit.
18 in.
(460 mm)
2
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
loc_small 2015-04
OM-265 270 Page 10
4-2. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
30 m (100 ft) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
mm2 (AWG)
45 m (150
ft)
60 m (200 ft)
60 − 100%
Duty Cycle
70 m (250
ft)
90 m (300
ft)
105 m (350
ft)
120 m (400
ft)
10 − 100% Duty Cycle
mm2 (AWG)
mm2 (AWG)
100
20 (4)
20 (4)
20 (4)
30 (3)
35 (2)
50 (1)
60 (1/0)
60 (1/0)
150
30 (3)
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
95 (3/0)
200
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
120 (4/0)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***For distances longer than those shown in this guide, call a factory applications representative.
Milan Ref. S-0007-L 2015−02
4-3. Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
. For welding output terminal connec1
tions see Sections 4-5 thru 4-7 for
typical connection processes.
2
output term1 2015−02
4-4. Remote 14 Receptacle Information
Socket*
A
B
K
J
I
A
Contactor control +15 volts DC.
B
Contact closure to A completes 15 volts DC
contactor control circuit and enables output.
C
Output to remote control; +10 volts DC output to
remote control.
REMOTE
OUTPUT
CONTROL
D
Remote control circuit common.
E
0 to +10 volts DC input command signal from
remote control.
A/V
F
Current feedback; +1 volt DC per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt DC per 10 volts output.
GND
G
+15 volts DC GND
CHASSIS
K
Chassis common.
15 VOLTS DC
H
C L N
M
D
G
E F
OUTPUT
CONTACTOR
956172131_1-A
Socket Information
* The remaining socket es are not used.
. If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the remote
control before the Panel or Remote contactor is turned on. Failure to do so will cause current to be controlled by the panel control, and the remote
hand control will not function.
OM-265 270 Page 11
4-5. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Weld Output Connections
!
Turn off power before making connections.
1
Positive (+) Weld Output
Terminal
Work Lead
2
Connect work lead to positive weld
output terminal.
5
3
4
4
3
1
Negative (−) Weld Output
Terminal
TIG Torch
Connect TIG torch to negative weld
output terminal.
5
Remote 14 Plug
2
Tools Needed:
21 mm (11/16, 1-1/8 in.)
4-6. Gas Connections
1
2
3
2
Remove cap, stand to side of
valve, and open valve slightly.
Gas flow blows dust and dirt
from valve. Close valve.
Regulator/Flowmeter
Install so face is vertical.
3
1
Flow Adjust
Typical flow rate is 15 CFH (cubic
feet per hour) (7.1 liters per minute).
Make sure flow adjust is closed
when opening cylinder to avoid
damage to the flowmeter.
4
Gas In Fitting
Connect hose from shielding gas
supply regulator/flowmeter to gas in
fitting. Fitting has 5/8-18 right-hand
threads.
5
Gas Out Fitting
Connect shielding gas hose from
torch to gas out fitting. Fitting has
3/8-19 BSPP right-hand threads.
4
5
Tools Needed:
21 mm (11/16, 1-1/8 in.)
OM-265 270 Page 12
4-7. Stick DCEP (Direct Current Electrode Positive)Weld Output Connections
!
Turn off power before making connections.
1
Negative (−) Weld Output
Terminal
Work Lead
2
Connect work lead to negative weld
output terminal.
3
3
4
1
Positive (+) Weld Output
Terminal
Electrode Holder
Connect electrode holder to positive weld output terminal.
2
4
4-8. Electrical Service Guide
. Actual input voltage cannot exceed -10% of minimum, or +10% of maximum input voltages indicated in table.
Elec Serv 2014−01
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
Three-Phase, 40% Duty Cycle
380−440 +/− 10%
Input Voltage (V)
15 − 17
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In Amperes
1
Time Delay Fuses 2
20
Normal Operating Fuses 3
25
Min Input Conductor Size In mm2 (AWG) 4
Max Recommended Input Conductor Length In Meters (Feet)
Min Grounding Conductor Size In AWG 4
2.5 mm2 (14)
45 (149)
2.5 mm2 (14)
Reference: 2014 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
310.15(B)(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.
OM-265 270 Page 13
4-9. Connecting 3-Phase Input Power
3
= GND/PE Earth Ground
4
7
2
L1
3
L2
5
L3
6
1
Tools Needed:
input2 2012−05 − 956172131_1-A
OM-265 270 Page 14
4-9. Connecting 3-Phase Input Power (Continued)
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
See rating label on unit and check input voltage available at site.
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
1
2
!
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
For Three-Phase Operation
4
Input Power Cord.
Disconnect Device (switch shown in the
OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding Terminal
5
6
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
3
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
7
Over-Current Protection
Select type and size of over-current protection using Section 4-8 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.
input2 2012−05
4-10. Connecting To 3-Phase Engine Generator w/400 Volt Output
Installation must meet all National and Local Codes − have only qualified persons make this installation.
. Obtain a 400 volt plug that matches the receptacle on the engine generator. Install the plug on the cord of the welding power source according
to the plug manufacturer’s instructions.
Generator Requirements
• Engine generator must provide the correct input amperage (see Section 4-8).
• Frequency must be between 50 and 60 Hz
NOTICE − Make sure welding power source is off during engine generator start-up. Do not turn on the welding power source until the generator has
reached normal operating speed.
OM-265 270 Page 15
SECTION 5 − OPERATION
5-1. Controls
3
4
5
6
7
8
9
10
2
11
1
26
25
27
24
23
22
21
20
19
12
13
18
1
Output Control Selector Switch
Use switch to select way of controlling unit
output. LED on the left illuminates when remote output is selected. Connect remote
control to Remote 14 receptacle (see Section 4-4). LED on the right illuminates when
panel control is selected.
8
17
14
16
15
Process Selector Switch
See Section 5-2 and/or 5-3.
9
Trigger Mode Selector Switch
See Section 5-5 for trigger mode settings.
10 Menu/VRD Selector Switch
Is lit when power is on.
Press and release switch to scroll through
welding parameters of the selected
process. Use Amperage/Parameter Adjustment control to change parameter values.
In Stick mode, push and hold switch for five
seconds to select or disable VRD (voltage
reduction device).
4
See Section 3-3.
2
Voltage/Amperage Control
Use switch to display welding voltage or
welding amperage on the display.
3
Power On Pilot Light
High Temperature Indicator Light
Light comes on if unit overheats. Once unit
has cooled down, welding can resume (see
Section 3-3).
5
Amperage/Voltage Parameter Display
(Meter)
11 Postflow Timer
See Section 5-6.
12 Final Current Indicator Light
See Section 5-6).
17 Remote 14 Receptacle
If desired, connect a remote control to the
Remote 14 receptacle See Section 4-4.
18 Amperage/Parameter Adjustment
Control
Use control to adjust welding amperage
(see Section 5-4) and welding parameters.
19 Background Current Indicator Light
See Section 5-7.
20 Slope Up Time Indicator Light
See Section 5-6.
21 Pulse Frequency (Hz) Indicator Light
See Section 5-7.
22 Hot Start/Arc Force Indicator Light
See Section 5-2.
23 Amperage Indicator Light
Meter displays actual amperage/voltage
while welding.
13 Slope Down Time Indicator Light
LED is lit while using the Amperage control
(see Section 5-4)
See Section 5-6).
6
24 Gas In Fitting
14 Gas Out Fitting
Connect hose from shielding gas supply
regulator/flowmeter to gas in fitting. Fitting
has 5/8-18 right-hand threads. See Section
4-6.
Generic Alarm LED
When lit or blinks indicates:
A. Lit plus continuous beep signal = input
overvoltage.
B. Blink plus continuous beep signal =
phase loss.
C. Blink plus intermittent beep signal = input
undervoltage.
7
Output Voltage Indicator Light
When lit indicates the presence of output
voltage.
See Section 4-6.
15 Negative Weld Output Receptacle
For Stick welding, connect work lead to this
receptacle. For TIG welding, connect torch
to this receptacle.
25 Input Power Cord
26 Power Switch
16 Positive Weld Output Receptacle
Use switch to turn unit on/off.
For Stick welding, connect electrode cable
to this receptacle. For TIG welding, connect
work cable to this receptacle.
Connection point for a Hydracool 270. See
Hydracool 270 Owner’s Manual.
27 Output Voltage Connection Hole
956172131_2-A
OM-265 270 Page 16
5-2. Preparing Unit For Stick (SMAW) Welding
1
2
3
4
9
5
5
6
7
8
9
6
Positive Weld Output Terminal
Remote 14 Receptacle
Negative Weld Output Terminal
Amperage/Parameter
Adjustment Control
Ammeter/Voltage Display
(Meter)
Process Selector Switch
MENU/VRD Selector Switch
Hot Start/Arc Force Light
Welding Amperage Light
Prepare unit for Stick welding as
follows:
8
7
Connect electrode holder and work
lead (see Section 4-7) . If desired,
connect a remote control to the Remote 14 receptacle (see Section
4-4). Turn power on. Allow time for
unit to complete its start-up cycle.
Press and release Process control
to select Stick welding and light corresponding LED.
4
Voltage Reduction Setting (VRD)
2
To change voltage reduction setting
(VRD), proceed as follows: press
and hold the MENU/VRD switch for
five seconds to select VRD (LED on)
or disable VRD (LED off). When Voltage Reduction is enabled, VRD is 12
volts.
Hot Start Setting
1
3
Use Hot Start to increase output amperage at the start of a weld to help
prevent electrode sticking. To
change Hot Start setting, proceed as
follows: while in the set-up menu,
press and release MENU/VRD
switch until Hot Start/Arc Force light
is on. The display meter will display
H. Use Amperage/Parameter control to adjust the Hot Start value.
Arc Force Setting
Use Arc Force to increase short-circuit amperage at low arc voltage. Set
at 0 for normal welding amperage.
Turn control clockwise to increase
short-circuit amperage. To change
Arc Force setting, proceed as follows: while in the set-up menu, press
and release MENU/VRD switch until
the Arc Force light is on. The display
meter will display A. Use the Amperage/Parameter control to adjust the
Arc Force value.
. Unit will automatically exit the
set-up menu if no activity is detected for more than five seconds. Press and hold the Menu/
VRD switch to re-enter set-up
mode.
Adjusting Welding Amperage
Use Amperage/Parameter Adjust
control to adjust welding amperage
(see Section 5-4).
956172131_3­A
OM-265 270 Page 17
5-3. Preparing Unit For TIG (GTAW) Welding
1
2
3
4
5
5
6
7
Positive Weld Output Terminal
Remote 14 Receptacle
Negative Weld Output Terminal
Amperage/Parameter
Adjustment Control
Ammeter/Voltage/Parameter
Display Meter
Process Selector Switch
Menu/VRD Selector Switch
Prepare Unit For TIG Welding As
Follows: connect electrode holder
and work lead (see Section 4-5) . If
desired, connect a remote control to
the Remote 14 receptacle (see Section 4-4). Turn power on. Allow time
for unit to complete its start-up cycle.
6
7
Press and release Process Selector
switch to select TIG and light corresponding LED.
Make gas connections (see Section
4-6).
Select Trigger Mode (see Section
5-5).
4
Adjust Sequencer Control Settings
(see Section 5-6).
Adjust Pulser Control Settings (TIG
HF) (see Section 5-7).
. While in the TIG mode and with
2
VRD active, the no load open
circuit voltage is 10.6 VDC. The
10.6 VDC is used to assist in
Lift-Arc starts.
1
3
Drawing #
OM-265 270 Page 18
5-4. Amperage Control
1
Amperage Control
Rotate control clockwise to increase amperage (5-270 amps).
2
Amperage Indicator Light
2
1
956172131_5-A
5-5. Trigger Mode Selection
1
Process Selector Switch
Rotate knob clockwise to increase
amperage (0-270 amps).
2
Current (A)
1
2
Remote 2T trigger Operation
Main Amps
Initial Slope
To change between 2T and 4T, proceed as follows: press and release
Trigger Mode selector switch until
desired trigger mode is selected. Indicator light begins flashing to confirm selected trigger mode.
Final Slope
Postflow
P
Trigger Mode Selector Switch
2T and 4T are used with the TIG
process. Select TIG (see Section
5-3).
Time
R
Current (A)
Remote 4T trigger Operation
Main Amps
Final Slope
Initial Slope
Initial Amps
Final Amps
Postflow
Time
P
R
P
R
956172131_7-A
OM-265 270 Page 19
5-6. Sequence Control Settings
2
3
4
Hot Start/Arc Force
Control
Amperage Control
1
5
6
1
Amperage/Parameter Adjustment
Control
2 Ammeter/Voltage/Parameter Display
(Meter)
3 Process Selector Switch
4 MENU/VRD Selector Switch
To enter Sequencer Control set-up mode
and scroll through parameters (slope up
time, weld amperage, slope down time, final current, and posflow)press and release
the MENU/VRD selector switch. Selected
parameter is displayed on the meter and the
corresponding LED lights. Turn Amperage/
Parameter Adjustment control to change
value of selected parameter. Value selected is displayed on the meter.
5
Slope Up Time
Is the amount of time it takes to slope up/
down from initial amperage to weld amperage. (min=0s, max=10s).
6
7
Weld Amperage
Slope Down Time
Is the amount of time it takes to slope up/
down from weld (main) amperage to final
amperage. (min=0s, max=15s).
7
8
9
8 Final Current
Is the amperage to which weld amperage
has sloped up/down to.
9 Postflow Time
Is the length of time gas flows after welding
stops
to
protect
weld
puddle
(min.0s-max.20s).
. Preflow time is 0.2 seconds.
. Unit will automatically exit the set-up
menu if no activity is detected for more
than five seconds. Press and hold the
Menu/VRD switch to re-enter set-up
mode.
956172131_8-A
OM-265 270 Page 20
5-7. Pulser Control Settings
1
2
3
5
7
6
1
Amperage/Parameter Adjustment
Control
2 Ammeter/Voltage/Parameter Display
(Meter)
3 Process Selector Switch
4 MENU/VRD Selector Switch
To enter Pulser set-up mode and scroll
through parameters, press and release the
MENU/VRD selector switch. Selected parameter is displayed on the meter and the
corresponding LED lights. Turn Amperage/
Parameter Adjustment control to change
value of selected parameter. Value selected is displayed on the meter.
5 Pulser LEDs
6
Background Current
Background Current controls the low pulse
of the weld amperage, which cools the weld
puddle and affects overall heat input. Background Current is set as a percentage of
peak amperage.
7
Pulse Frequency (Hz)
Pulse Frequency controls weld bead appearance. (min=0 Hz, max=500Hz).
Application:
Pulsing refers to the alternating raising and
lowering of the weld output at a specific
rate. The raised portions of the weld output
are controlled in width, height, and frequency, forming pulses of weld output. These
pulses and the lower amperage level between them (called the background current) 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.
. Unit will automatically exit the set-up
menu if no activity is detected for more
than five seconds. Press and hold the
Menu/VRD switch to re-enter set-up
mode.
956172131_9-A
OM-265 270 Page 21
5-8. HF Current Settings
3
2
4
1
5
Ihf: HF Current
Iweld: Welding Current
Current (A)
Ihf<Iweld
IWeld
HF Current Setting (A)
V/A
Automatic HF Current (A)
V/A
Slope Up Time
HF Current
Automatically Set For 25A For 20 ms
HF Current
Is Selected
HF Current
Range Value
Time
Current (A)
Ihf>Iweld
IWeld
5A
Slope Up Time
1
Slope Up Indicator Light
2
Hot Start/Arc Force
3
Ammeter/Voltage/Parameter Display
(Meter)
To enter HF current control settings, press
and hold the MENU/VRD Selector Switch
for five seconds. Hot Start/Arc Indicator
LED lights. Meter displays H and two digital
numbers indicating the amperage range
value. Turn Amperage/Parameter Adjustment control knob to change the amperage
range value. Turn control knob clockwise to
increase value. To enter HF automatic setup menu proceed as follow: While in the set
up menu, turn knob counterclockwise to the
minimum value. Meter displays AUTO, and
the amperage value is automatically set by
the power source (25A for 20ms).
Understanding the A/T curves:
Iweld: Welding Amperage (see Section 5-4)
Ihf: HF Amperage
Time
• Ihf < Iweld: HF Amperage value is maintained for 20 ms and then reaches welding amperage within the slope time.
• Ihf > Iweld: HF Amperage value is maintained for 20 ms and then falls down to the
minimum value of 5A. After that, welding
amperage is reached within the slope
time.
. Unit will automatically exit the set-up
menu if no activity is detected for more
than five seconds. Press and hold the
MENU/VRD switch to re-enter set-up
mode.
956172131_12-A
OM-265 270 Page 22
5-9. TIG Lift-Arc Settings
See Section 4-5 for TIG Lift-Arc
weld output connections.
To exit TIG HF mode and enter TIG
Lift-Arc mode proceed as follows:
Turn off welding power source.
Connect TIG torch to Remote-14
receptacle (see Section 4-5).
Press and hold torch trigger while
turning on welding power source.
Release torch trigger.
Welding power source is now in the
Lift-Arc mode.
5-10. Resetting Unit To Factory Default Settings
. This procedure will delete all
operator specified parameters,
and recall all factory parameters.
1
2
Menu/VRD Switch
Power Switch
To reset unit to factory default settings proceed as follows:
1
Turn power off.
Turn power on while pressing and
holding Menu/VRD switch.
Factory defaults settings are now
restored. TIG HF is the default
mode setting.
2
956172131_15-A
OM-265 270 Page 23
5-11. Lift-Arc Start Procedure
Lift-Arc Start
With Lift-Arct selected, start arc
as follows:
“Touch”
TIG Electrode
2
Workpiece
Turn gas on. Touch tungsten electrode to workpiece at weld start
point. Hold electrode to workpiece for 1-2 seconds, and slowly
lift electrode. Arc is formed when
electrode is lifted.
Lift-Arc Start Method
1
1
2
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting
contaminated.
1−2
Seconds
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to replace the scratch method.
Do NOT Strike Like A Match!
5-12. Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as follows:
1
2
3
Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted
to high. If electrode sticks to workpiece, use
a quick twist to free it.
1
!
2
3
OM-265 270 Page 24
Electrode
Workpiece
Arc
For models with stock number 907
220, normal open-circuit voltage (80
volts) is present before electrode
touches workpiece.
For models with stock numbers 907 036 and
907 037, normal open-circuit voltage is not
present before electrode touches workpiece; only a low sensing voltage is present
between electrode and workpiece.
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
!
Disconnect power before maintaining.
. Maintain more often during severe conditions.
A. Welding Power Source
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Δ = Repair
l = Replace
Every
3
Months
nl Labels
n l Gas Hoses
Every
3
Months
nΔ lCables And Cords
Every
6
Months
!
Do not remove case when
blowing out inside of unit
(see Section 6-2) .
~:Durning heavy service, clean monthly.
6-2. Blowing Out Inside Of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
OM-265 270 Page 25
6-3. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-9).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-9).
Check for proper input power connections (see Section 4-9).
No weld output; Output LED on.
Input voltage outside acceptable range of variation (see Section 4-8).
No weld output; Overtemp LED on.
Unit overheated. Allow unit to cool with fan On (see Sections 3-3).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-2).
Clean and tighten all weld connections (see Section 4-2).
Fan not operating.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wandering arc
Use proper size tungsten (see Section 9).
Use properly prepared tungsten (see Section 9).
Reduce gas flow rate (see Section 4-5).
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Allow adequate postflow time to shield tungsten while it cools, after welding stops.
Check and tighten all gas fittings (see Section 4-5).
Water in torch. Refer to torch manual.
Notes
OM-265 270 Page 26
SECTION 7 − ELECTRICAL DIAGRAMS
Figure 7-1. Circuit Diagram
956172132_B
OM-255 441 Page 27
SECTION 8 − HIGH FREQUENCY
8-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG
high_freq 5/10 − S-0693
8-2. Installation Showing Possible Sources Of HF Interference
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
5
6
Best Practices
Not Followed
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-265 270 Page 28
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
8-3. Recommended Installation To Reduce HF Interference
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
Best Practices Followed
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 (clean paint
from around hole in case, and use case
screw), work output terminal, line disconnect device, input supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
OM-265 270 Page 29
SECTION 9 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2013-10
Whenever possible and practical, use DC weld output instead of AC weld output.
9-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
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, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (.25 mm)
Up to 25
Up to 20
.020 in. (.50 mm)
15-40
15-35
.040 in. (1 mm)
25-85
20-80
1/16 in. (1.6 mm)
50-160
50-150
3/32 in. (2.4 mm)
130-250
135-235
1/8 in. (3.2 mm)
250-400
225-360
5/32 in. (4.0 mm)
400-500
300-450
3/16 in (4.8 mm)
500-750
400-500
1/4 in. (6.4 mm)
750-1000
600-800
♦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.
9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter 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.
Radial Grinding
Causes Wandering Arc
2-1/2 Times
Electrode Diameter
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.
Wrong Tungsten
Preparation
4
Ideal Tungsten Preparation − Stable Arc
3
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
OM-265 270 Page 30
SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW)
10-1. 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°
Make sure workpiece is clean before
welding.
1
2
Work Clamp
Place as close to the weld as possible.
3
4
5
6
10−15°
4
5
6
10−25°
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten according
to Section 9.
Guidelines:
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.
1/16 in.
3/16 in.
Bottom View Of Gas Cup
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-265 270 Page 31
10-2. 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
15°
Tilt torch
Remove rod
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
10-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20°
90°
70°
75°
20°
10°
15°
Corner Joint
Lap Joint
20-40°
90°
75°
75°
15°
15°
30°
ST-162 003 / S-0792
OM-265 270 Page 32
SECTION 11 − STICK WELDING (SMAW) GUIDELINES
11-1. 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
sonal protective clothing.
Workpiece
Make sure workpiece is clean before welding.
2
Constant Current
Welding Power Source
Work Clamp
Place as close to the weld as
possible.
3
Electrode
Before striking an arc, insert an
electrode in the electrode holder. A
small diameter electrode requires
less current than a large one. Follow recommendations of the electrode manufacturer when setting
weld amperage (see Section 11-2).
5
4
2
3
6
1
7
4
Insulated Electrode Holder
5
Electrode Holder Position
6
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. Correct
arc length is related to electrode diameter. Examine the weld bead to
determine if the arc length is correct.
Arc length for 1/16 and 3/32 in. diameter electrodes should be about
1/16 in. (1.6 mm); arc length for 1/8
and 5/32 in. electrodes should be
about 1/8 in. (3 mm).
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
stick 2015 - 04 − 151 593
OM-265 270 Page 33
6013
7014
7018
7024
Ni-Cl
308L
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
MED
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
AMPERAGE
RANGE
250
200
150
POSITION
6010
&
6011
100
50
DIAMETER
ELECTRODE
11-2. Electrode and Amperage Selection Chart
MIN. PREP, ROUGH
HIGH SPATTER
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
11-3. Striking an Arc
1
!
Weld current starts when electrode touches workpiece.
1
2
3
Electrode
Workpiece
Arc
Scratch Technique
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
3
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.
1
2
3
S-0049 / S-0050
OM-265 270 Page 34
11-4. Positioning Electrode Holder
1
2
After learning to start and hold
an arc, practice running beads
of weld metal on flat plates using
a full electrode.
1
10°-30°
90°
End View Of Work Angle
Side View Of Electrode
Angle
Hold the electrode nearly perpendicular to the work, although
tilting it ahead (in the direction of
travel) will be helpful.
2
90°
. To produce the best results,
hold a short arc, travel at a
uniform speed, and feed the
electrode downward at a
constant rate as it melts.
Groove Welds
10°-30°
45°
1
2
45°
Fillet Welds
S-0060
11-5. 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
11-6. 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-265 270 Page 35
11-7. 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
11-8. 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
11-9. Welding Lap Joints
1
2
Electrode
Single-Layer Fillet Weld
Move electrode in circular motion.
30°
Or Less
30°
Or Less
1
1
2
3
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
S-0063 / S-0064
OM-265 270 Page 36
11-10. Welding Groove (Butt) Joints
1
Tack Welds
Prevent butt joint distortion by tack
welding the materials in position
before final weld.
Workpiece distortion occurs when
heat is applied locally to a joint.
One side of a metal plate will “curl”
up toward the weld. Distortion will
also cause the edges of a butt joint
to pull together ahead of the electrode as the weld cools.
1
2
1/16 in.
(1.6 mm)
Square Groove Weld
3
Single V-Groove Weld
4
Double V-Groove Weld
Materials up to 3/16 in. (5 mm)
thick can often be welded without
special preparation using the
square groove weld. However,
when welding thicker materials it
may be necessary to prepare the
edges (V-groove) of butt joints to
ensure good welds.
30°
The single or double V-groove
weld is good for materials 3/16 −
3/4 in. (5-19 mm) thick. Generally,
the single V-groove is used on materials up to 3/4 in. (19 mm) thick
and when, regardless of thickness,
you can weld from one side only.
Create a 30 degree bevel with oxyacetylene or plasma cutting equipment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
4
3
2
S-0062
11-11. Welding Tee Joints
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.
3
1
2
45°
Or
Less
1
2
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
11-8. Remove slag before making
another weld pass.
3
S-0060 / S-0058-A / S-0061
OM-265 270 Page 37
11-12. Weld Test
1
2
3
Strike the weld joint in the direction shown. A good weld
bends over but does not break.
3
If the weld breaks, examine it to determine the cause.
If the weld is porous (many holes), the arc length was
probably too long.
3
If the weld contains bits of slag, the arc may have been
too long or the electrode was moved incorrectly which
allowed molten slag to be trapped in the weld. This may
happen on a V-groove joint made in several layers and
calls for additional cleaning between layers.
2 To 3 in.
(51-76 mm)
1/4 in.
(6.4 mm)
Vise
Weld Joint
Hammer
2
1
2 To 3 in.
(51-76 mm)
2
1
If the original beveled surface is visible the material was
not fully melted which is often caused by insufficient
heat or too fast a travel speed.
S-0057-B
11-13. 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.
OM-265 270 Page 38
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
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-265 270 Page 39
SECTION 12 − PARTS LIST
. Hardware is common and not available unless listed.
2
22
3
4
18
5
20
23
21
24
19
25
17
6
1
16
15
12
11
13
26
30
14
32
31
33
10
9
7
28
29
27
38
8
34
37
35
39
41
42
45
44
26
36
47
48
46
40
49
27
51
43
50
49
956172131_11-B
Figure 12-1. Main Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
. . . . . . . . . . . 057116003
. . . . . . . . . . +156122096
. . . . . . . . . . . . . . 179310
. . . . . . . . . . . 956172114
. . . . PC5 . 057084194
. . . . PC1 . 057084200
. . . . . . . . . . . 656043046
. . . . . . . . . . . 057028131
. . . . . . . . . . . . . . 193919
. . . . . . . . . . . 356029261
. . . . . . . . . . . 156118097
. . . . PC3 . 057084201
. . . . PC6 . 057084202
. . . . . . . . . . . 156122097
. . . . . . . . . . . 156005192
. . . . PC2 . 028069196
OM-265 270 Page 40
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Strap, Shoulder Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Gen. Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Side STH 270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Capacitor And Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Inverter Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw Cap, 14−Pin Rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, 14−Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Front, STH 270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Cad Fod HF 270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulkhead, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Power Interconnecting Board . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly (continued)
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
+
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
. . . . . . . . . . . 156005200
. . . . PC8 . 057084203
. . . . PC4 . 057084198
. . . . . S1 . . . . . 244920
. . . . . . . . . . . 156118098
. . . . . . . . . . . 356029265
. . . . . . . . . . . 656089046
. . . . . . . . . . . 256071011
. . . . . . . . . . . . . . 246624
. . . . . . . . . . . . . . 231279
. . . . . . . . . . . . . . 230155
. . . . . LF . . 156160003
. . . . . FM . . 057035023
. . . . . . . . . . . 156122098
. . . . GSV . 056061037
. . . . . . . . . . . 756033060
. . . . . . . . . . . 156005194
. . . . . . . . . . . 056082105
. . . D1, D2 028069158
. . . . PC7 . 057084204
. . . . . L1 . . 057015110
. . . . . L2 . . 057098025
. . . . . T2 . . 058021170
. . . . . T1 . . 058021164
. . . . HD1 . 056167009
. . . . . . . . . . . 056076260
. . . . . . . . . . . . . . 246623
. . . . . . . . . . . 956172116
. . . . . . . . . . . 956172115
. . . . . . . . . . . 216031080
. . . . . . . . . . . 316031024
. . . . . . . . . . . 156006094
. . . . . . . . . . . . . . 250946
. . . . . . . . . . . . . . 246626
. . . . . . . . . . . 057052053
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Bracket, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Cooling On Demand Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, TGL 3PST 40A 600 VAC SCR Term Wide TGL . . . . . . . . . . . . . . .
Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Rear, STH 270 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief, M25x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Primary 4 Core 2.5 MM 2 3.3 MT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bezel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting, Gas−Clip Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Valve MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Core, Toroidal, 13x26x28.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan, 230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bulkhead, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, 230VAC 4w 1/8in. FF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator, Secondary Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Sink, Secondary Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, HF Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer, Toroidal 400 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Probe, 400 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dinse, Socket, Female, 50 MMQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bezel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar, 3x15 L.110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar, 4x20 L.110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base, Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, Connector, 5/8 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
2
1
4
1
1
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-265 270 Page 41
Notes
TM-216 869 Page 42
Dynasty 350/700, Maxstar 350/700
Notes
Notes
TM-216 869 Page 44
Dynasty 350/700, Maxstar 350/700
Effective January 1, 2015
(Equipment with a serial number preface of MF or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, ITW Welding Products Italy warrants to its original retail
purchaser that new Miller equipment sold after the effective date
of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed. If notification is submitted as an
online warranty claim, the claim must include a detailed
description of the fault and the troubleshooting steps taken to
identify failed components and the cause of their failure.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser or one
year after the equipment is shipped to a European distributor or
twelve months after the equipment is shipped to an International
distributor.
1.
5 Years Parts — 3 Years Labor
*
2.
3 Years — Parts and Labor
*
*
*
*
*
3.
Auto-Darkening Helmet Lenses (No Labor)
Migmatic 175
HF Units
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
5.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
Inverter Power Sources (Unless Otherwise Stated)
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Transformer/Rectifier Power Sources
2 Years — Parts
*
*
*
4.
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules with
exclusion of STR, Si, STi, STH and MPi series.
Automatic Motion Devices
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.)
Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
Motor-Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Powered Air Purifying Respirator (PAPR) Blower
Unit (No Labor)
Racks
Running Gear and Trailers
Subarc Wire Drive Assemblies
Water Coolant Systems
Work Stations/Weld Tables (No Labor)
6 Months — Parts
*
Batteries
6.
90 Days — Parts
*
*
*
*
*
*
Accessory (Kits)
Canvas Covers
Induction Heating Coils and Blankets
MIG Guns
Remote Controls
Replacement Parts (No Labor)
*
*
Spoolmate Spoolguns
Cables and Non-Electronic Controls
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, switches, slip
rings, relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at ITW Welding Products
Group Europe 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.
milan_warr 2015-01
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
Country
Zip/Postal Code
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
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Italy S.r.l.
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
© 2015 Miller Electric Mfg. Co. 2015−01
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: [email protected]−welding.it
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