Syncrowave 250 DX / 350 LX

213117AF
2010−08
Processes
TIG (GTAW) Welding
ENGLISH
OM-363
Arc Welding Power Source
Syncrowave 250 DX / 350 LX
With Optional Running Gear And Cooler
CE And Non-CE Models
Visit our website at
www.MillerWelds.com
File: TIG (GTAW)
ESPAÑOL
Description
FRANÇAIS
Stick (SMAW) Welding
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
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
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-2. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8
3-4. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3-5. Cooler Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Welding Power Source Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
3-7. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
3-8. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
3-9. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
3-11. Shielding Gas Connections And 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
3-12. TIG Connections With A Two-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
3-13. TIG Connections With A One-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) . . . . . . . . . . . . .
15
16
3-15. Front Panel Display For TIG AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
3-16. Optional Cooler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
19
3-18. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . .
20
3-19. Front Panel Display For Stick AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
3-20. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-21. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
24
3-22. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
4-1. Controls (350 LX Nameplates Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
28
4-3. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
4-4. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
30
4-6. 4T, 4T Momentary, And Mini Logic Trigger Operation (Requires Optional Sequence Controls) . . . . . .
32
4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
4-8. Selecting TIG Starting Characteristics Using Syncro-Startt Technology . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
38
4-10. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
4-11. Preflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
4-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models) . . . . . . . . . . . . . . . . . . . . .
4-13. Sequence Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
43
4-14. Initial Time Control And Initial Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
TABLE OF CONTENTS
4-15. Final Slope Control And Final Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Spot Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Welding Power Source Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Supplementary Protector CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting The Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Routine Maintenance For Optional Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Troubleshooting The Optional Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . .
9-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . .
9-2. Preparing Tungsten Electrode For Welding With Phase Control Machines . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − PARTS LIST FOR OPTIONAL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
45
45
46
47
48
48
48
49
50
50
51
52
52
53
54
57
57
57
58
59
59
59
60
60
61
62
64
70
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Syncrowave 250
Syncrowave 350
Stock Number
907408
907409
Council Directives:
2006/95/EC Low Voltage
2004/108/EC Electromagnetic Compatibility
Standards:
IEC 60974­: 2005 Arc Welding Equipment – Welding Power Sources
IEC 60974­3: 2007 Arc Welding Equipment – Arc Striking and Stabilizing Devices
IEC 60974­10: 2004 Arc Welding Equipment – Electromagnetic Compatibility Requirements
EN 50445 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic
fields (0 Hz – 300Hz) BS EN 50445:2008.
US Signatory:
June 29, 2010
_________________________________________________________________________________
David A. Werba
MANAGER, PRODUCT DESIGN COMPLIANCE
248779­A
Date of Declaration
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2010−03
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
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.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
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!
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).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
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 for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced 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.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
OM-363 Page 1
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
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.
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.
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.
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).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
OM-363 Page 2
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect ImplantedMedical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
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.
Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
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.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
MOVING PARTS can injure.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
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.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
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.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
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-363 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.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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,
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).
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, 4221 Walney Road, 5th Floor,
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).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.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). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or 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-363 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.
ENGLISH
SECTION 2 − DEFINITIONS
2-1. Warning Label Definitions
Warning! Watch Out! There are possible
hazards as shown by the symbols.
1
1.1
1.2
1.3
2
2.1
Electric shock from welding electrode
or wiring can kill.
Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
Protect yourself from electric shock by
insulating yourself from work and
ground.
Disconnect input plug or power before
working on machine.
Breathing welding fumes can be
hazardous to your health.
Keep your head out of the fumes.
1
1.1
2
2.1
2.2 Use forced ventilation or local exhaust
to remove the fumes.
2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause explosion
or fire.
3.1 Keep flammables away from welding.
Do not weld near flammables.
3.2 Welding sparks can cause fires. Have
a fire extinguisher nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any closed
containers.
4 Arc rays can burn eyes and injure
skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
1.2
1.3
2.2
4
2.3
welding helmet with correct shade of
filter. Wear complete body protection.
5 Become trained and read the
instructions before working on the
machine or welding.
6 Do not remove or paint over (cover)
the label.
7 Welding current creates an electric
and magnetic field (EMF) around the
welding circuit and welding equipment.
Follow compliance boundaries to stay
within EMF exposure limits in an
occupational environment.
7.1 Read the Owner’s Manual for EMF
information.
4.1
5
lk
lk
ks;dglk
s;dg ks;dg
ldfgkks;ldfgk
s;dglk
s;lgk s;ldfg
dlks;ldfg
ds;lggks
ld
Aslgkd
Aslgkkgs
s;
Asldhf sgkds;lgk
S;ld
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
3
3.1
3.2
3.3
6
7
7.1
245694-A
2-2. WEEE Label (For Products Sold Within The EU)
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.
OM-363 Page 5
2-3. Symbols And Definitions
Some symbols are found only on CE products.
A
V
Amperes
Panel−Local
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
Volts
Do Not Switch
While Welding
Arc Force (DIG)
Background Amps
Output
Circuit Breaker
Remote
Temperature
Protective Earth
(Ground)
Alternating Current
High Frequency Start
Water Input
Postflow Timer
Preflow Timer
High Frequency Continuous
Water Output
Gas (Supply)
Gas Output
Gas Input
Increase/Decrease
Of Quantity
On
Off
Percent
Direct Current
Balance Control
Maximum Cleaning
Maximum
Penetration
Electrode Positive
Electrode
Negative
Final Slope
Meter
Single-Phase
Conventional Load
Voltage
Line Connection
U0
Rated No Load
Voltage (Average)
U1
Primary Voltage
I1
Primary Current
I2
Rated Welding
Current
IP
Degree Of
Protection
I1eff
Maximum Effective
Supply Current
S
Up
OM-363 Page 6
U2
X
I1max
Duty Cycle
Rated Maximum
Supply Current
1
1
Hz
Single-Phase
Combined AC/DC
Power Source
Hertz
Electrode
Work
Thickness Gauge
Spark Gap
Seconds
Final Amperage
Initial Time
Initial Amperage
Pulse Percent On
Time
Spot Time
Lift-Arc
Trigger Hold
Pulser On-Off
Pulse Frequency
Rated peak starting voltage
4T
4 Step Trigger Operation Sequence
Input
ENGLISH
SECTION 3 − INSTALLATION
3-1. Important Information Regarding CE Products (Sold Within The EU)
!
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.
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.
3-2. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the rear 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.
OM-363 Page 7
3-3. Selecting A Location
Movement
1
OR
2
Location And Airflow
3
1
18 in.
(460 mm)
18 in. (460 mm)
!
Falling Unit Can Cause Injury.
Use lifting eye to lift unit only, NOT
running gear, gas cylinders, or any
other accessories.
Use equipment of adequate capacity
to lift and support unit.
1
2
If using lift forks to move unit, be sure
forks are long enough to extend
beyond opposite side of unit.
Lifting Eye
Lifting Forks
3
!
Special installation may be required
where gasoline or volatile liquids
are present − see NEC Article 511 or
CEC Section 20.
!
Do not move or operate unit where
it could tip.
Use lifting eye or lifting forks to move unit.
If using lifting forks, extend forks beyond
opposite side of unit.
Line Disconnect Device
Locate unit near correct input power supply.
Ref. 117 264-C / 803 584-B
OM-363 Page 8
D
Dimensions
A
C
B
G
C
Front
E
Height
36-1/4 in. (921 mm)
Width
23 in. (584 mm)
Length
28 in. (711 mm)
A
25 in. (635 mm)
B
1-25/64 in. (35 mm)
C
1-5/8 in. (41 mm)
D
22 in. (559 mm)
E
20 in. (508 mm)
F
22-1/4 in. (565 mm)
G
1-1/8 in. (29 mm)
H
1/2 in. (13 mm) Dia
F
H
803 616-A
Weight
400 lbs (181 kg) For 250 DX Models
496 lbs (225 kg) For 350 LX Models
3-5. Cooler Specifications
Cooler Specifications
Cooler Tank Capacity
3 gallons (11.4 L)
Coolant Flow Rate 1 liter per minute (1.1 quart)
Use With Torches Rated Up To 400 Amperes
3-6. Welding Power Source Specifications
A. For 350 LX Models
Rated
Welding
Output
NEMA
Class I (60)
− 300
Amperes, 32
Volts AC,
60% Duty
Cycle
NEMA Class
II (40) − 350
Amperes, 34
Volts AC,
40% Duty
Cycle
Amperes Input at AC Balanced Rated Load Output,
50/60 Hz, Single-Phase
PFC
**
200V 220V 230V 400V 440V 460V 520V 575V KVA
KW
Amperage
Range
Rated
Peak
Max Starting
OCV Voltage
(Up)
(Uo)
No
PFC
125
3.3*
103
2.2*
110
2.0*
57
1.5*
52
1.2*
55
1.7*
43
1.0*
42
1.1*
25.0
0.9*
10.6
0.6*
With
PFC
92
77*
77
67*
78
69*
40
36*
39
33*
38
34*
33
28*
31
27.2*
18.0
16.6*
10.5
0.6*
15 KV
No
PFC
146
3.3*
120
2.2*
128
2.6*
66
2.5*
60
1.2*
65
1.7*
51
1.0*
50
1.1*
29.5
0.9*
13.7
0.4*
15 KV
With
PFC
114
77*
95
67*
94
69*
49
36*
47
33*
47
34*
40
28*
38
27.2*
21.7
16.6*
13.3
0.6*
15 KV
3 − 400A
3 − 400A
80V
80V
15 KV
*While idling
**Power Factor Correction
Arc striking device is designed for manual guided operations
OM-363 Page 9
ENGLISH
3-4. Dimensions And Weights
B. For 250 DX Models
Amperes Input at AC Balanced Rated
Load Output, 60 Hz, Single-Phase
Rated
Welding
Output
PFC
**
200V
NEMA Class
I (40) − 200
Amperes, 28
Volts AC,
60% Duty
Cycle
No
PFC
88
77
*3.3
*2.8
With
PFC
60
52
*55.3
*49.5
NEMA Class
II (40) − 250
Amperes, 30
Volts AC,
40% Duty
Cycle
No
PFC
110
96
*3.3
*2.8
With
PFC
82
71
*55.3
*49.5
230V
460V
575V
KVA
38
31
17.6
8.6
*1.5
*1.1
*.59
*.29
26
21
12.06
8.11
*24.5
*19.6
*11.2
*.39
48
38
21.98
11.76
*1.5
*1.1
*.59
*.29
35
28
16.32
11.81
*24.5
*19.6
*11.2
*1.93
KW
Amperage
Range
Max
OCV
(Uo)
Rated
Peak
Starting
Voltage
(Up)
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
Amperage
Range
Max
OCV
(Uo)
Rated
Peak
Starting
Voltage
(Up)
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
Amperage
Range
Max
OCV
(Uo)
Rated
Peak
Starting
Voltage
(Up)
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
*While idling
**Power Factor Correction
Arc striking device is designed for manual guided operations
Amperes Input at AC Balanced Rated
Load Output, 50/60 Hz, Single-Phase
Rated
Welding
Output
PFC
**
220V
NEMA Class
I (40) − 200
Amperes, 28
Volts AC,
60% Duty
Cycle
No
PFC
82
45
*3.0
*1.6
With
PFC
61
34
*45.9
*25.1
NEMA Class
II (40) − 250
Amperes, 30
Volts AC,
40% Duty
Cycle
No
PFC
100
55
*3.0
*1.6
81
44
*45.9
*25.1
With
PFC
400V
440V
520V
KVA
41
35
17.6
8.6
*1.4
*1.2
*.59
*.29
31
26
12.06
8.11
*22.8
*23.2
*11.2
*.39
50
42
21.98
11.76
*1.4
*1.2
*.59
*.29
40
34
16.32
11.81
*22.8
*23.2
*11.2
*1.93
KW
*While idling
**Power Factor Correction
Arc striking device is designed for manual guided operations
Amperes Input at AC Balanced Rated
Load Output, 50 Hz, Single-Phase
Rated
Welding
Output
PFC
**
200V
NEMA Class
I (40) − 175
Amperes, 27
Volts AC,
60% Duty
Cycle
No
PFC
80
69
*3.3
*2.8
With
PFC
52
45
22
18
10.3
7.3
*55.3
*49.5
*24.5
*19.6
*11.2
*.39
NEMA Class
II (40) − 225
Amperes, 29
Volts AC,
40% Duty
Cycle
No
PFC
101
88
44
35
20.2
10.2
*3.3
*2.8
*1.5
*1.1
*.59
*.29
With
PFC
74
64
32
26
14.7
10.1
*55.3
*49.5
*24.5
*19.6
*11.2
*1.93
230V
460V
575V
KVA
35
28
15.9
7.4
*1.5
*1.1
*.59
*.29
*While idling
**Power Factor Correction
Arc striking device is designed for manual guided operations
OM-363 Page 10
KW
Duty Cycle is the percentage of 10
minutes that the unit can weld at rated
load without overheating.
If unit overheats, output stops, front
panel voltmeter/ammeter displays a
HLP3 or HLP5 message (see Section
6-1), and cooling fans run. Wait fifteen
minutes for unit to cool. Reduce amperage or duty cycle before welding.
250 DX Models
NOTICE − Exceeding duty cycle can
damage unit and void warranty.
40% Duty Cycle At 250 Amperes
4 Minutes Welding
60% Duty Cycle At 200 Amperes
6 Minutes Welding
6 Minutes Resting
Overheating
4 Minutes Resting
A
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 / Ref. 116 198
350 LX Models
40% Duty Cycle At 350 Amperes
4 Minutes Welding
Overheating
60% Duty Cycle At 300 Amperes
6 Minutes Welding
6 Minutes Resting
4 Minutes Resting
A
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 / 190 276
OM-363 Page 11
ENGLISH
3-7. Duty Cycle And Overheating
3-8. Volt-Ampere Curves
A. For 250 DX Models
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
10
0
0
50
100
150
200
250
300
350
400
450
0
0
50
AMPS
100
150
200
250
300
350
400
450
AMPS
205 631 / 205 632
B. For 350 LX Models
350 Amperes Models
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
ssb1.1 10/91 − ST-190 277 / ST-190 278
OM-363 Page 12
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
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Select weld cable sizes for pulsing applications at peak amperage value.
Weld Cable Size** and Total Cable (Copper) Length in
Weld Circuit Not Exceeding***
Weld Output
Terminals
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn,
damaged,
undersized, or poorly
spliced cables.
100 ft (30 m) or Less
60 − 100% Duty
Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
150
3 (30)
3 (30)
2 (35)
1 (50)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
10 − 100% Duty Cycle
AWG (mm2)
Work
Ref. 803 588-B
* This
200 ft
(60 m)
10 − 60% Duty
Cycle
Welding Amperes
Electrode
150 ft
(45 m)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-G 2009−08
OM-363 Page 13
ENGLISH
3-9. Weld Output Terminals And Selecting Cable Sizes*
3-10. Remote 14 Receptacle Information
!
Socket*
Turn off power before
connecting to receptacle.
A
Contactor control 24 volts DC.
B
Contact closure to A completes 24 volts DC
contactor control circuit and enables output.
C
Output to remote control; 0 to +10 volts DC output
to remote control.
REMOTE
OUTPUT
CONTROL
D
Remote control/feedback circuit common.
E
0 to +10 volts DC input command signal from
remote control.
A/V
F
Current feedback; +1 volt DC per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt DC per 10 volts output.
GND
K
Chassis common.
24 VOLTS DC
A
B
J
K
OUTPUT
CONTACTOR
I
Socket Information
H
C L N
D M
G
E F
A
Ref. 803 588-B
*The remaining sockets are not used.
3-11. Shielding Gas Connections And 115 Volts AC Duplex Receptacle
4
!
Turn Off power before connecting to receptacle.
1
Gas Valve In Connection
Located on rear of unit.
2
3
5
Gas Valve Out Connection
Connections have 5/8-18 righthand threads.
3
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
Tools Needed:
5/8, 3/4, 1-1/8 in.
4
Regulator/Flow Gauge
Connect regulator/flow gauge to
gas cylinder.
Connect customer supplied gas
hose between regulator/flow gauge
and gas in fitting.
5
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour).
6
115 V 15 Amp AC Receptacle
Receptacle is protected from overload by circuit breaker CB1 (see
Section 5-2).
2
Rear View
Front View
OM-363 Page 14
6
1
Ref. 803 588-B / Ref. 803 585-B / Ref. 157 858
!
Turn Off power before making
connections.
1
Gas-In Connection
Connect gas hose from gas supply to
gas-in connection.
2
2
Output Selector Switch (See
Section 4-2)
Switch is shown in DCEN (direct current electrode negative) position for
TIG HF Impulse DCEN welding. For
front panel control display, see Section
3-14. For TIG AC welding, place switch
in AC position (see Section 4-2). For
TIG AC front panel control display, see
Section 3-15.
5
6
3
1
3
Work Weld Output Terminal
Connect work lead to work weld output
terminal.
4
4
Tools Needed:
11/16 in., (21 mm)
Remote 14 Receptacle
Connect desired remote control to Remote 14 receptacle (see Section 3-10).
5
Electrode Weld Output Terminal
Connect TIG torch to electrode weld
output terminal.
6
Gas-Out Connection
Connect torch gas hose to gas-out
fitting.
803 586-C
3-13. TIG Connections With A One-Piece Air-Cooled Torch
!
Turn Off power before making
connections.
1
Gas-In Connection
Connect gas hose from gas supply to
gas−in connection.
2
2
Output Selector Switch (See
Section 4-2)
Switch is shown in DCEN (direct current electrode negative) position for
TIG HF Impulse DCEN welding. For
front panel control display, see Section
3-14. For TIG AC welding, place switch
in AC position (see Section 4-2). For
TIG AC front panel control display, see
Section 3-15.
5
6
3
3
1
Work Weld Output Terminal
Connect work lead to work weld output
terminal.
4
Remote 14 Receptacle
Connect desired remote control to Remote 14 receptacle (see Section 3-10).
4
5
Tools Needed:
11/16 in., (21 mm)
Electrode Weld Output Terminal
Connect TIG torch to electrode weld
output terminal.
6
Gas-Out Connection
Connect torch gas hose to gas-out
fitting.
803 615-B
OM-363 Page 15
ENGLISH
3-12. TIG Connections With A Two-Piece Air-Cooled Torch
3-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)
1
Front Panel
Correct front panel display for basic TIG HF Impulse DCEN
welding.
For all front panel switch pad
controls: press switch pad to
turn on light and enable
function.
Green on nameplate indicates a
TIG function (see Section 4-1 for
description of controls).
1
(CE Nameplate)
1
OM-363 Page 16
1
For all front panel switch pad
Front Panel
Correct front panel display for
basic TIG AC welding.
controls: press switch pad to
turn on light and enable
function.
Green on nameplate indicates a
TIG function (see Section 4-1 for
description of controls).
1
(CE Nameplate)
1
OM-363 Page 17
ENGLISH
3-15. Front Panel Display For TIG AC
3-16.
Optional Cooler Connections
!
Disconnect cooler plug from
welding power source receptacle before filling.
1
Cap
Remove cap and fill tank with three
gallons of distilled or deionized water for operations above 32 F (0
C), or three gallons of Miller coolant
part no. 043 810.
2
Gas Out Connection
Connect TIG torch gas hose to gas
out fitting.
3
5
4
3
Connect TIG torch to electrode
weld output terminal.
8
4
Remote 14 Receptacle
Connect remote control to receptacle if desired.
2
1
Electrode Weld Output
Terminal
7
6
5
Work Weld Output Terminal
Connect work lead to work weld
output terminal.
6
Water-In (From Torch)
Connection
Connect torch water-out (red) hose
to welding power source water-in
connection.
7
Water-Out (To Torch)
Connection
Connect torch water-in (blue) hose
to welding power source water-out
connection.
8
115 VAC Cord
Connect plug to 115 vac receptacle
to provide power to the cooler.
804 994-B
Tools Needed:
GTAW Or Where
HF* Is Used
Application
3-1/2
Gal
Low Conductivity Coolant
No. 043 810**;
Distilled Or Deionized Water
OK Above 32 F (0 C)
Coolant
*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protect to -37 F (-38C) and resist algae growth.
NOTICE − Use of any coolant other than those listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.)
OM-363 Page 18
11/16 in., (21 mm for CE units)
!
Turn Off power before making connections.
1
Work Weld Output Terminal
Connect work lead to work weld
output terminal.
2
Electrode Weld Output
Terminal
Connect electrode holder to electrode weld output terminal.
3
Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Section 3-10).
4
2
4
Output Selector Switch (See
Section 4-2)
Switch is shown in DCEP (direct
current electrode positive) position
for Stick DCEP welding. For front
panel control display, see Section
3-18. For Stick AC welding, place
switch in AC position. For Stick AC
front panel control display, see Section 3-19.
3
1
Tools Needed:
11/16 in., (21 mm), 3/4 in
803 587-B
OM-363 Page 19
ENGLISH
3-17. Stick Connections
3-18. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
1
For all front panel switch pad
Front Panel
Correct front panel display for
basic Stick DCEP welding.
controls: press switch pad to
turn on light and enable
function.
Gray on nameplate indicates a
Stick function (see Section 4-1
for description of controls).
1
(CE Nameplate)
1
OM-363 Page 20
1
For all front panel switch pad
Front Panel
Correct front panel display for
basic Stick AC welding.
controls: press switch pad to
turn on light and enable
function.
Gray on nameplate indicates a
Stick function (see Section 4-1
for description of controls).
1
(CE Nameplate)
1
OM-363 Page 21
ENGLISH
3-19. Front Panel Display For Stick AC
3-20. Electrical Service Guide
A. For 250 DX Models
Input amperage may be higher than shown in table when Balance Control is in an unbalanced position.
All values in both tables were calculated at 60% duty cycle.
Actual input voltage cannot exceed  10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range,
damage to unit may occur.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
50/60 Hertz Models
Without Power Factor Correction
Input Voltage (V)
200
220
230
400
440
460
520
575
Input Amperes (A) At Rated Output
88
82
77
45
41
38
35
31
Time-Delay Fuse 2
125
125
125
70
60
60
50
45
Normal Operating (Fast) Fuse 3
125
125
125
70
60
60
50
45
4
6
6
8
8
10
10
10
167
(51)
137
(42)
153
(47)
305
(93)
369
(112)
281
(86)
352
(107)
439
(134)
6
6
6
8
10
10
10
10
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
Circuit Breaker 1
Min Input Conductor Size In AWG4
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
50/60 Hertz Models
With Power Factor Correction
Input Voltage (V)
200
220
230
400
440
460
520
575
Input Amperes (A) At Rated Output
60
61
52
34
31
26
26
21
Time-Delay Fuse 2
90
90
80
50
45
40
40
30
Normal Operating (Fast) Fuse 3
90
90
80
50
45
40
40
30
8
8
8
10
10
10
10
12
87 (26)
102
(31)
115
(35)
226
(69)
274
(84)
308
(94)
383
(117)
295
(90)
8
8
8
10
10
10
10
12
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
Circuit Breaker 1
Min Input Conductor Size In
AWG4
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-363 Page 22
Input amperage may be higher than shown in table when Balance Control is in an unbalanced position.
All values in both tables were calculated at 60% duty cycle.
Actual input voltage cannot exceed  10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range,
damage to unit may occur.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
50/60 Hertz Models
Without Power Factor Correction
Input Voltage (V)
200
220
230
400
440
460
520
575
Input Amperes (A) At Rated Output
125
103
110
57
52
55
43
42
Time-Delay Fuse 2
150
125
125
70
70
60
60
50
Normal Operating (Fast) Fuse 3
175
175
175
90
90
80
70
70
3
3
4
8
8
8
8
8
151
(46)
182
(56)
171
(52)
246
(75)
298
(91)
326
(99)
416
(127)
509
(155)
6
6
6
8
8
8
8
8
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
Circuit Breaker 1
Min Input Conductor Size In AWG4
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
50/60 Hertz Models
With Power Factor Correction
Input Voltage (V)
200
220
230
400
440
460
520
575
Input Amperes (A) At Rated Output
92
77
78
40
39
38
33
31
Time-Delay Fuse 2
110
100
90
50
50
45
40
35
Normal Operating (Fast) Fuse 3
125
125
125
70
60
60
50
45
4
6
6
8
8
8
10
10
145
(44)
119
(36)
130
(40)
263
(80)
318
(97)
347
(106)
300
(91)
367
(112)
6
6
6
8
10
10
10
10
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
Circuit Breaker 1
Min Input Conductor Size In AWG4
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-363 Page 23
ENGLISH
B. For 350 LX Models
3-21. Placing Jumper Links
Label found on 250 DX models with the following stock numbers:
907194, 907194-021 and, 907194-031
Label found on 350 LX models with the following stock numbers:
907198, 907198-011, 907198-021, and 907198-031
2
!
Check input voltage available at
site.
1
1
Disconnect and lockout/tagout input power before
installing or moving jumper
links.
Jumper Link Label
Check label − only one label is on
unit.
2
083 566-F
Or
Label found on 250 DX models with the following stock numbers:
907195, 907195-021 and, 907195-031
Jumper Links
Move jumper links to match input
voltage.
Close and secure access door, or
go on to Section 3-22.
Label found on 350 LX models with the following stock numbers:
907199, 907199-021, and 907199-031
230 VOLTS
460 VOLTS
575 VOLTS
1
L
L
L
L
L
L
010 587-D
Or
Label found on 250 DX models with stock number 907408
Label found on 350 LX models with stock number 907409
1
191 440-A
Tools Needed:
3/8 in.
Ref. 803 585-C
OM-363 Page 24
ENGLISH
3-22. Connecting Input Power
1
8
=GND/PE Earth Ground
10
7
9
L1
L2
4
1
6
2
6
5
Tools Needed:
3/8 in.
4
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit.
!
Make input power connections to the
welding power source first.
!
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
See rating label on unit and check input voltage available at site.
1
Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 3-20. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
803 585-C
3
Welding Power Source Input Power Connections
Disconnect Device Input Power Connections
2
7
Disconnect Device (switch shown in
OFF position)
8
Disconnect Device (Supply) Grounding
Terminal
Strain Relief
Route conductors (cord) through strain relief
and tighten screws.
3
Machine Grounding Terminal
4
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
Connect green or green/yellow grounding
conductor to welding power source grounding
terminal first.
9
5
Welding Power Source Line Terminals
10 Overcurrent Protection
6
Input Conductors L1 And L2
Select type and size of overcurrent protection
using Section 3-20 (fused disconnect switch
shown).
Connect input conductors L1 and L2 to welding power source line terminals.
Close and secure access door on welding
power source.
Disconnect Device Line Terminals
Connect input conductors L1 and L2 to
disconnect device line terminals.
Close and secure door on line disconnect device. Remove lockout/tagout device, and
place switch in the On position.
OM-363 Page 25
SECTION 4 − OPERATION
4-1. Controls (350 LX Nameplates Shown)
A. For 200/230/460 Volts And Non CE Units
11
1
2
3
4
5
6
12
10
9
7
Top row of lights in upper left corner are
On for SMAW. Bottom row are On for
GTAW.
Green on nameplate indicates a TIG function,
Gray indicates a Stick function.
1
Process Control
See Section 4-3.
2
Amperage Control
See Section 4-4.
3 Output Control
See Section 4-5.
4 Start Mode Control
See Section 4-9.
5
Voltmeter And Ammeter
Voltmeter displays average voltage (to the
nearest 0.1 V) at the weld output terminals.
Use meter to preset amperage. Meter displays average weld amperage output of unit
to nearest ampere when welding.
Meters are self-calibrating. No adjustment
8
available.
6 Amperage Adjustment
Control
Use control to adjust amperage, and preset
amperage on ammeter. This control may be
adjusted while welding.
For remote amperage control, front panel
control setting is the maximum amperage
available. For example: If front panel control
is set to 200 amps, the range of the remote
amperage control is 3 to 200 amps for 250 DX
models, and 3 to 200 amps for 350 LX
models.
For pulse welding, use Amperage Adjust
control to select from 3-300 amps of peak amperage for 250 DX models, or 3−400 amps of
peak amperage for 350 LX models (see Section 4-12).
For spot welding, use Amperage Adjust
control to select from 3-310 amps for 250 DX
models, or 3−400 amps for 350 LX models
(see Section 4-16).
7 Output Selector Switch
See Section 4-2.
8 Power Switch
Use switch to turn unit Off and On.
9 Postflow Time Control
Use control to set length of time (0−50 seconds) gas flows after welding stops. It is important to set enough time to allow gas to flow
until after the tungsten and weld puddle has
cooled down.
Application:
Postflow is required to cool the tungsten and
weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance (approximately 1 second per 10 ampere of welding
current).
10 Balance/DIG Control
See Section 4-10.
11 Pulser Controls (Optional on 250 DX
model)
See Section 4-12.
12 Sequence Controls (Optional)
See Section 4-13.
217 264-A / 213 106-A
OM-363 Page 26
ENGLISH
B. For CE Units
11
1
2
3
4
5
6
12
10
9
7
Top row of lights in upper left corner are
On for SMAW. Bottom row are On for
GTAW.
Green on nameplate indicates a TIG function,
Gray indicates a Stick function.
1
Process Control
See Section 4-3.
2
Amperage Control
See Section 4-4.
3
Output Control
See Section 4-5.
4
Start Mode Control
See Section 4-9.
5
Voltmeter And Ammeter
Voltmeter displays average voltage (to the
nearest 0.1 V) at the weld output terminals.
Use meter to preset amperage. Meter displays average weld amperage output of unit
to nearest ampere when welding.
8
Meters are self-calibrating. No adjustment
available.
6 Amperage Adjustment
Control
Use control to adjust amperage, and preset
amperage on ammeter. This control may be
adjusted while welding.
For remote amperage control, front panel
control setting is the maximum amperage
available. For example: If front panel control
is set to 200 A, the range of the remote amperage control is 3 to 200 amps for 250 DX models, and 3 to 200 amps for 350 LX models..
For pulse welding, use Amperage Adjust
control to select from 3-300 amps of peak amperage for 250 DX models, or 3−400 amps of
peak amperage for 350 LX models (see Section 4-12).
For spot welding, use Amperage Adjust
control to select from 3-310 amps for 250 DX
models, or 3−400 amps for 350 LX models
(see Section 4-16).
7 Output Selector Switch
See Section 4-2.
8 Power Switch
Use switch to turn unit Off and On.
9 Postflow Time Control
Use control to set length of time (0−50 seconds) gas flows after welding stops. It is important to set enough time to allow gas to flow
until after the tungsten and weld puddle has
cooled down.
Application:
Postflow is required to cool the tungsten and
weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance (approximately 1 second per 10 ampere of welding
current).
10 Balance/DIG Control
See Section 4-10.
11 Pulser Controls (Optional on 250 DX
model)
See Section 4-12.
12 Sequence Controls (Optional)
See Section 4-13.
215 460-A / 218 584-A
OM-363 Page 27
4-2. Output Selector Switch
1
1
Output Selector Switch
!
Do not use AC output in
damp areas, if movement is
confined, or if there is danger of falling. Use AC output
ONLY if required for the
welding process, and then
use a remote control.
!
Do not change position of
switch while welding or
while under load.
Use switch to select (DCEN) Direct
Current Electrode Negative, AC, or
(DCEP) Direct Current Electrode
Positive output.
Changing position of Output Selector switch may change Process
control, Current control, and Start
Mode control, and may require
changing Output control settings to
properly function with latest Output
Selector switch setting.
4-3. Process Control
1
Process Control
Use control to select Stick or TIG
process.
2
(CE Nameplate)
STICK Process
For Stick process, press button to
toggle LED to Stick position.
2
3
TIG Process
For TIG process, press button to
toggle LED to TIG position.
Lit LED indicates selected mode.
1
3
When Output Selector switch position changes, LED may change
position, based upon last selection.
1
Ref. 217 264-A / Ref. 215 460-A
4-4. Amperage Control
1
Amperage Control
Use control to select front panel or
remote amperage control.
2
(CE Nameplate)
Front Panel Position
For front panel amperage control,
press button to toggle LED to Panel
position.
2
3
Remote Amperage Position
For remote amperage control,
press button to toggle LED to Remote position (see Section 3-10).
Lit LED indicates selected mode.
1
OM-363 Page 28
3
1
When Output Selector switch position changes, LED may change
position, based upon last selection.
ENGLISH
Notes
OM-363 Page 29
4-5. Output Control
Remote (Standard)Torch Trigger Operation
(CE Nameplate)
2
2
1
1
Current (A)
Remote (Standard)Torch Trigger Operation
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Foot Or Finger
Remote Control
Release For
Maintained Switch
1
Output Control
2
!
Weld output terminals are energized when power is On, and Output On LED is lit.
For remote output control, press button to
toggle LED to Remote position (see Section 3-10).
Use control to select front panel, trigger
hold, or remote output control.
Lit LED indicates selected mode.
For weld output, press button to toggle LED
to On position.
OM-363 Page 30
Remote Trigger (Standard) Operation
Release Foot Or
Finger Remote
Control
If On/Off only type trigger is used, it must be
a maintained switch. All functions become
active.
Torch trigger operation is as shown.
Application: Use Remote Trigger when
the operator desires to use a foot pedal or
finger amperage control.
Initial weld amperage and final amperage
is controlled by the remote device, not by
the welding power source.
When Output Selector switch (see Section
4-2) position changes, Output control LED
will always switch to Remote.
ENGLISH
Trigger Hold (2T)
(CE Nameplate)
3
Current (A)
2T Torch Trigger Operation
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release Trigger
In Less Than 3/4 Sec.
Push & Release Trigger
In Less Than 3/4 Sec.
If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode (see previous page).
If arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 6-1).
3 Trigger Hold
For trigger hold operation, press button to
toggle LED to Trigger Hold position.
Torch trigger operation is as shown.
When a foot or finger remote control is
connected to the welding power source,
only trigger input is functional, as amperage is controlled by the welding power
source.
Application: Trigger Hold (2T) can help
to reduce operator fatigue when long extended welds are made.
OM-363 Page 31
4-6. 4T, 4T Momentary, And Mini Logic Trigger Operation (Requires Optional Sequence
Controls)
4T Torch Trigger Operation
If unit is equipped with optional Sequence
Controls (see Section 4-13), 4T trigger
method is available.
lows the operator to toggle between weld
current and final current without breaking
the arc.
4T torch trigger operation is as shown.
When a remote switch is connected to the
welding power source, only trigger input is
functional. Amperage is controlled by the
welding power source.
While in 4T mode, there is a feature available during the main weld sequence that al-
Application:
Use 4T trigger method when the functions
of a remote current control are desired, but
only a remote on/off control is available.
Select 4T trigger method according to Section 4-7.
Current (A)
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Trigger
Release
Trigger
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger
Release
Trigger
4T Momentary Torch Trigger Operation
If unit is equipped with optional Sequence
Controls (see Section 4-13), 4T Momentary trigger method is available.
4T Momentary torch trigger operation is as
shown.
While in 4T Momentary mode, once the operator toggles out of weld current and begins final slope, toggling again will break
the arc and go to postflow.
When a remote switch is connected to the
welding power source, only trigger input is
functional. Amperage is controlled by the
welding power source.
Application:
Use 4T Momentary trigger method when
the functions of a remote current control are
desired, but only a remote on/off control is
available.
Select 4T Momentary trigger method according to Section 4-7.
Current (A)
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release
Trigger
OM-363 Page 32
Push & Release
Trigger
Push & Release
Trigger
Push & Release
Trigger
ENGLISH
Mini Logic Operation
If unit is equipped with optional Sequence
Controls (see Section 4-13), Mini Logic operation is available.
Torch trigger operation is as shown.
During Mini Logic welding operation, the
weld amperage can be manually changed
from the initial amps level to the main weld
amps level by pressing and releasing the
torch trigger in less than 3/4 seconds.
When a remote switch is connected to the
welding power source, only trigger input is
functional. Amperage is controlled by the
welding power source.
Application: This ability to change amperage levels without either initial slope or final
slope, gives the operator the opportunity to
adjust filler metal without breaking the arc.
Select Mini Logic according to Section 4-7.
Weld Amps
Final Slope
Initial Amps
Initial Amps
Final Slope
Rate
Preflow
Push & Hold
Trigger
Push & Hold
Trigger For More
Than 3/4 Sec.
Release Trigger
Push & Release
Trigger In Less
Than 3/4 Sec.
Postflow
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger For More
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
OM-363 Page 33
4-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control
1
2
Output Control
Power Switch
2
To reconfigure Trigger Hold, turn Off
power, push and hold Output control
button and turn On power switch.
Hold button for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and meters
display [SEL] [H−2].
Front Panel
Press Output control button to
change functions. Active function will
be displayed on amperage (bottom)
meter.
3
1
Meter Displays
Meter displays for the different functions will be as shown.
Press torch trigger or turn power Off
to save setting.
SEL
Proceed to Section 4-6 for 4T Operation.
Proceed to Section 4-6 for Mini Logic
operation.
H−2
Proceed to Section 4-6 for 4T Momentary operation.
These features are only available
when optional Sequencer is
installed.
SEL
H-4E
Momentary
= 4T
(See Section 4-6)
SEL
SEL
= Mini Logic (See Section 4-6)
= 4T (See Section 4-6)
H−4
H4L
3
OM-363 Page 34
ENGLISH
2
(CE Nameplate)
Front Panel
1
SEL
H−2
SEL
= 4T Momentary
SEL
= Mini Logic (See Section 4-6)
= 4T (See Section 4-6)
(See Section 4-6)
H-4E
SEL
H−4
H4L
3
OM-363 Page 35
4-8. Selecting TIG Starting Characteristics Using Syncro-Startt Technology
4
1
E−
−2−
2
3
Use this function to select desired TIG starting characteristics.
1 Start Mode
2 Power Switch
3 Output Selector Switch
4 Meters
To select or change TIG starting characteristics, proceed as follows: turn Off power.
Place Output Selector switch in desired position (each position, DCEN, AC, or DCEP has
three applicable start characteristics options). Push and hold Start Mode button and
OM-363 Page 36
turn On power. Hold button for approximately
7 seconds (or until software version number_
_ _ _ _ _-_ clears meters).
The TIG LED and all four Start LEDs will light,
and the meters will display [E−] [−2−], [AC]
[−2−], or [EP] [−2-], depending on position of
Polarity switch.
Press Start Mode button again to step
through the three start characteristics
choices. Amperage (bottom) meter displays
active choice 1= light start, 2=medium/normal
start, 3=high/hot start.
Press torch trigger or turn Off power to save
setting.
Application:
Select 1 (light/soft start) − when welding at
low amperages on thin gauge material.
Select 2 (medium/normal start) − factory default setting used for most welding applications.
Select 3 (high/hot start) − when welding at
high amperages on thick materials with a
large diameter tungsten.
ENGLISH
(CE Nameplate)
1
4
E−
−2−
2
3
OM-363 Page 37
4-9. Start Mode
(CE Nameplate)
2
1
1
3
4
Lift-Arc Start Method
“Touch”
1−2
Seconds
Do NOT Strike Like A Match!
1
2
Start Mode
OFF Position
For SMAW welding, press button to toggle
LED to Off position.
For GTAW welding, use control to select
Off for no HF, Lift-Arc, HF for arc starting
only, or continuous HF.
Application:
When Off is selected, use the scratch
method to start an arc for both the SMAW
and GTAW processes.
When Lift-Arc is selected, start arc as
follows:
3
TIG Electrode
4
Workpiece
Touch tungsten electrode to workpiece at
weld start point, enable output with torch
trigger, foot control, or hand control. Hold
electrode to workpiece for 1-2 secOM-363 Page 38
onds, and slowly lift electrode. An arc will
form when electrode is lifted.
turns off when arc is started, and turns on
whenever arc is broken to help restart arc.
Shielding gas begins to flow when electrode touches work piece.
Application:
Normal open-circuit voltage is not present
before tungsten electrode touches workpiece, only a low sensing voltage is present between electrode and workpiece.
The solid state output contactor does not
energize until after electrode is touching
workpiece. This allows electrode to touch
workpiece without overheating, sticking,
or getting contaminated.
Application:
Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted, or to replace the scratch method.
HF Start is used when the DCEN GTAW
process is required.
When HF Continuous is selected, start
arc as follows:
High frequency turns on when output is
energized and remains on for duration of
weld.
Application:
HF Continuous is used when the AC
GTAW process is required.
Lit LED indicates selected mode.
When HF Start is selected, start arc as
follows:
When Output Selector switch position
changes, LED may change position,
based upon last selection.
High frequency turns on to help start arc
when output is enabled. High frequency
Some start methods may not be available
for all processes.
1
Balance/DIG Control
Balance Control (AC GTAW):
Control changes the AC output
square wave. Rotating the control
towards 10 provides deeper penetration. Rotating the control towards
0 provides more cleaning action of
the workpiece.
(CE Nameplate)
When the control is in the Balanced
position, the wave shape provides
equal penetration and cleaning
action.
1
1
Application:
When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only
a minimal amount, approximately a
0.10 in (2.5mm) of etched zone
along the weld toes is required.
Set control to 3 and adjust as necessary. Joint configuration, set-up,
process variables, and oxide thickness may affect setting.
Balance Control Examples
Output Waveforms
Setting
Balanced
3
50% Electrode
Positive
50% Electrode
Negative
Max Penetration
10
Max Cleaning
0
32% Electrode
Positive
68% Electrode
Negative
55% Electrode
Positive
45% Electrode
Negative
Arc
Arc rectification can occur when
welding above 200 amps and/or
while welding with helium gas. If this
condition occurs, increasing the
Balance control towards maximum
penetration may help to restabilize
the arc.
DIG Control (AC And DC SMAW):
When set at 0, short-circuit amperage at low arc voltage is the same
as normal welding amperage.
When setting is increased, shortcircuit amperage at low arc voltage
increases. Set control at 2 and adjust as necessary. Joint configuration, set-up, and process variables
may affect setting.
Application:
Control helps arc starting or making
vertical, or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking
while welding.
Ref. S-0795-A
OM-363 Page 39
ENGLISH
4-10. Balance/DIG Control
4-11. Preflow Time Control
3
00.4
4
1
SEL
2
Use control to set length of time (0.2, 0.4, 0.6,
0.8, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0
seconds) gas flows before welding starts.
1
Process Control
2
Power Switch
3
Meters
OM-363 Page 40
To change preflow time, proceed as follows:
Turn power off. Push and hold Process Control button and turn On power. Hold button for
approximately 7 seconds (or until software
version number_ _ _ _ _ _-_ clears meters).
4 TIG LED
The TIG LED will light and the meters will display [o.4] [SEL]. The factory preflow default
setting is 0.4 seconds. To change preflow
time, press and release Process Control button until desired time is displayed on meters.
Application:
Preflow is used to purge the immediate weld
area of atmosphere. Preflow also aids in consistent arc starting.
ENGLISH
(CE Nameplate)
3
4
1
00.4
SEL
2
OM-363 Page 41
4-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models)
1
On/Off Control
Use control to turn pulse function
On and Off.
2
Pulser ON LED
LED is lit when pulser function is
enabled.
2
3
5
4
3
1
Background Amps
Use Background Amps control to
set the low pulse of the weld amperage, which cools the weld puddle
and affects overall heat input.
Background Amps is set as a percentage of peak amperage.
4
Pulse Frequency
Ranges from 0.25−10.0 pps
(pulses per second). Control is
used to determine appearance of
weld bead.
5
(CE Nameplate)
2
4
3
1
5
Peak Time
A range of 5−95% of each pulse
cycle can be spent at the peak amperage level.
Peak amperage (3-310 amps for
250 DX models, and 3−400 amps
for 350 LX models), is set with the
Amperage Adjustment control (see
Section 4-1). Peak amperage is the
highest welding amperage allowed
to occur in the pulse cycle. Weld
penetration varies directly with
peak amperage.
6
6
Pulsed Output Waveforms
Example shows affect changing
the Peak Time control has on the
pulsed output waveform.
Application:
Percent (%) Peak
Time Control Setting
Pulsed Output Waveforms
PPS
(50%)
Bkg Amp
Balanced
Peak Amp
More Time
At Peak
Amperage
More Time At
Background
Amperage
OM-363 Page 42
(80%)
(20%)
Pulsing refers to the alternating
raising and lowering of the weld
output at a specific rate. The raised
portions of the weld output are controlled in width, height, and frequency, forming pulses of weld output.
These pulses and the lower amperage level between them (called the
background amperage) alternately
heat and cool the molten weld
puddle. The combined effect gives
the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls
can be adjusted while welding.
Pulsing can also be used for filler
material addition technique training.
1
Initial Time Control
See Section 4-14.
2
5
3
1
Initial Amperage Control
See Section 4-14.
3
Final Slope Control
See Section 4-15.
4
Final Amperage Control
See Section 4-15.
5
Spot Time Control
See Section 4-16.
4
2
(CE Nameplate)
5
1
2
3
4
OM-363 Page 43
ENGLISH
4-13. Sequence Controls (Optional)
4-14. Initial Time Control And Initial Amperage Control
1
Initial Time Control
Indicator light is on when Initial
Time control function is active.
Initial Sequence control function is
inactive when Spot Time function is
active.
Use control to select 0−15 seconds
of start time.
(CE Nameplate)
1
2
1
Initial Amperage Control
Indicator Light is on when Initial Sequence control function is active.
Initial Amperage control function is
inactive when Spot Time function is
active.
Use control to select a starting amperage (3−400 amps) that is different from the weld amperage. Initial
Amperage can be used with or
without a remote control (Initial Amperage and Initial Time control settings will override a remote control
device).
Application:
2
2
Initial Amperage can be used while
GTAW welding to assist in preheating cold material prior to depositing
filler material, or to ensure a soft
start. Initial Amperage can also be
used for SMAW to ensure a more
consistent arc strike.
Function is enabled, when LED is
lit.
OM-363 Page 44
1
Final Slope Control
Indicator light is on when Final Slope
control function is active.
Final Slope control function is inactive
when Spot Time function is active.
Use control to reduce amperage over
a set period of time (0−15 seconds) at
the end of the weld cycle when NOT
using a remote current control.
(CE Nameplate)
2
1
Final Amperage Control
Indicator light is on when Final Amperage control function is active.
Final Amperage control function is inactive when Spot Time function is active (see Section 4-16).
Final amperage is the amperage to
which weld amperage has sloped
down to (0−100% of amperage set on
Amperage Adjust control).
Application:
Final Slope should be used while
GTAW welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
2
This applies if the operator is using an
on/off only type control to start and
stop the welding process.
Do not use this function with a foot or
finger amperage control.
Function is enabled, when LED is lit.
4-16. Spot Time Control
(CE Nameplate)
1
1
Spot Time Control
Indicator light is on when Spot Time
function is active. When Spot Time function is active, Initial Time, Initial Amperage, Final Slope, and Final Amperage
functions are inactive (see Section
4-13).
1
Used with the (GTAW) TIG Spot process, generally with a direct current
electrode negative (DCEN) set-up.
Use control to select 0−15 seconds of
spot time.
Use Amperage Adjust control (see Section 4-1) to set amperage.
Application:
TIG spot welding is used for joining thinner materials that are in close contact
with the fusion method. A good example
would be joining coil ends.
Function is enabled, when LED is lit.
OM-363 Page 45
ENGLISH
4-15. Final Slope Control And Final Amperage Control
4-17. Timer/Cycle Counter
1 2 3
1
2
3
4 5 6
1 2 3
4
4 5 6
1 Amperage Control
2 Output Control (Contactor)
To read timer/cycle counter, hold Amperage and Output (contactor) buttons while
turning on power. When machine first
powers up, the displays will show the
OM-363 Page 46
software number and revision for the first
seven seconds. It will then show arc time
and cycle count.
3 Timer Display
The hours and minutes are displayed on
the volt and amp meters for the first five
seconds, and are read as 1, 234 hours
and 56 minutes.
4 Cycle Display
The cycles are displayed on the volt and
amp meters for the next five seconds,
and are read as 123, 456 cycles.
ENGLISH
4-18. Resetting Unit To Factory Default Settings (All Models)
1
2
3
4
5
Process Control
Amperage Control
Output Control
Start Control
Power Switch
To reset all welding power source functions to
original factory settings, turn power off. Push
and hold the Process, Amperage, Output, and
Start controls and turn On power. Hold switch
pads for approximately 7 seconds (or until
software version number _ _ _ _ _ _-_clears
meters).
1
2
3
4
5
OM-363 Page 47
SECTION 5 − MAINTENANCE
5-1. Routine Welding Power Source Maintenance
!
Disconnect power before maintaining.
Maintain more often during severe conditions.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
= Repair
= Replace
Every
3
Months
Labels
Weld Terminals
Gas Hoses
Every
3
Months
 Cables And Cords
Every
6
Months
0.008
(0.203 mm)
Durning heavy service, clean monthly.
* Adjust or clean spark gap
5-2. Supplementary Protector CB1
1
!
Turn off power before resetting breaker.
1
Supplementary Protector CB1
If CB1 opens, high frequency and
output to the 115 volts AC duplex
receptacle stop. Press button to reset CB1.
Ref. 803 588-B
OM-363 Page 48
!
1
Turn Off welding power
source and disconnect and
lockout/tagout input power
before adjusting spark gaps.
Remove right side panel..
2
1
Tungsten End Of Point
Replace point if tungsten end disappears; do not clean or dress
tungsten.
2
4
Spark Gap
Normal spark gap is 0.008 in (0.203
mm).
If adjustment is needed, proceed as
follows:
3
3
Adjustment Screws
Loosen screws. Place gauge of
proper thickness in spark gap.
4
Pressure Point
Apply slight pressure at point until
gauge is held firmly in gap. Tighten
screws. Adjust other gap.
Reinstall right side panel.
Tools Needed:
0.008 in. (0.203 mm)
803 592-C
3/8 in.
5/32 in.
OM-363 Page 49
ENGLISH
5-3. Adjusting Spark Gaps
SECTION 6 − TROUBLESHOOTING
6-1. Voltmeter/Ammeter Help Displays
0
V
1
V
2
V
3
V
4
V
5
V
HLP
HLP
HLP
HLP
HLP
HLP
A
A
A
A
A
A
−−3
−−4
−−5
−−0
6
V
−−2
−−1
7
V
8
V
9
V
HLP
HLP
HLP
HLP
A
A
A
A
−−9
−10
−11
−12
All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.
0
Help 0 Display
Indicates a short in the thermal protection circuitry located on the
transformer/stabilizer of the unit.
1
Help1 Display
An SCR overcurrent or undercurrent condition has occurred.
Turn power off and back on to correct condition.
2
Help 2 Display
Indicates an open in the thermal protection circuitry located on
the transformer/stabilizer of the unit.
3
Help 3 Display
Indicates the transformer/stabilizer of the unit has overheated.
The unit has shut down to allow the fan to cool it (see Section
3-7). Operation will continue when the unit has cooled.
OM-363 Page 50
4 Help 4 Display
Indicates an open in the thermal protection circuitry located on
the rectifier assembly of the unit.
5 Help 5 Display
Rectifier assembly has overheated. The unit has shut down to
allow the fan to cool unit (see Section 3-7). Operation will continue when the unit has cooled.
6 Help 9 Display
Indicates a short in the thermal protection circuitry located on the
rectifier assembly of the unit.
7 Help 10 Display
Indicates Remote Output control is activated. Release Remote
Output control to clear help message.
8 Help 11 Display
Output Selector switch is not in correct position (see Section
4-2).
9 Help 12 Display
Indicates a non-allowable set-up of the front panel.
NOTICE − The remedies listed below are recommendations only. If these remedies do
not fix the trouble with your unit, have a Factory Authorized Service Agent check unit.
There are no user serviceable parts inside unit.
Refer to Section 6-1 for any Help (HLP) message displayed on voltmeter/ammeter.
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-22).
Check and replace line fuse(s), if necessary (see Section 3-22).
Check for proper input power connections (see Section 3-22).
Check for proper jumper link position (see Section 3-21).
No weld output; unit on.
If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 4-1).
Check, repair, or replace remote control.
Have Factory Authorized Service Agent check unit.
Unit provides only maximum or
minimum weld output.
Make sure Amperage control is in proper position (see Section 4-1).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 3-9).
Have Factory Authorized Service Agent check unit.
Clean and tighten all weld connections.
Check position of Output Selector control (see Section Figure 4-1).
If using remote control, check position of Amperage Adjustment control (see Section 4-1).
No control of weld output.
If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 4-1).
Make sure Amperage control is in proper position (see Section 4-1).
No output from duplex receptacle RC2
and no high frequency.
Reset circuit breaker CB1 (see Section 5-2).
Lack of high frequency; difficulty in
starting GTAW arc.
Reset circuit breaker CB1 (see Section 5-2).
Select proper size tungsten (see Section 9).
Be sure torch cable is not close to any grounded metal.
Check cables and torch for cracked insulation or bad connections. Repair or replace.
Check spark gaps (see Section 5-3).
Wandering arc − poor control of
direction of arc.
Reduce gas flow rate.
Select proper size tungsten (see Section 9).
Properly prepare tungsten (see Section 9).
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
Check for water in torch, and repair torch if necessary.
Fan not operating.
Unit equipped with Fan-On-Demand. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.
OM-363 Page 51
ENGLISH
6-2. Troubleshooting The Welding Power Source
6-3. Routine Maintenance For Optional Cooler
!
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Every
Month
= Repair
Disconnect power
before maintaining.
= Replace
NOTICE − Clean coolant strainer. Severe conditions may require more frequent cleaning
(continuous use, high/low temperatures, dirty
environment, etc.). Failure to properly
clean coolant strainer voids pump warranty.
Coolant Strainer
Heat Exchanger Fins
Every
Six
Months
Unreadable Labels
Cracked Hoses
Change Coolant If Using Water (See
Section 6-5)
Every
Twelve
Months
Change Coolant (If Using Miller Coolant) (See Section 6-5)
6-4. Troubleshooting The Optional Cooler
Trouble
Coolant system does not work.
Remedy
Be sure input power cord is plugged in to energized receptacle.
Check line fuses or circuit breaker, and replace or reset if necessary.
Motor overheated. Unit starts running when motor has cooled.
Have Factory Authorized Service Agent check motor.
Decreased or no coolant flow.
Add coolant.
Check for clogged hoses or coolant filter.
Disconnect pump, and check for sheared coupling. Replace coupling if necessary.
OM-363 Page 52
!
Disconnect power
before maintaining.
1
Coolant Filter
Unscrew housing to clean filter.
Changing coolant: Drain coolant by
tipping unit forward. Fill with clean
water and run for 10 minutes. Drain
and refill.
NOTICE − If replacing hoses, use
hoses compatible with ethylene
glycol, such as Buna-n, Neoprene,
or Hypalon. Oxy-acetylene hoses
are not compatible with any product
containing ethylene glycol.
1
GTAW Or Where
HF* Is Used
Application
3-1/2
Gal
801 195-A / Ref. 801 194
Low Conductivity Coolant
No. 043 810**;
Distilled Or Deionized Water
OK Above 32 F (0 C)
Coolant
*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protect to -37 F (-38C) and resist algae growth.
NOTICE − Use of any coolant other than those listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.)
OM-363 Page 53
ENGLISH
6-5. Coolant Maintenance
SECTION 7 − ELECTRICAL DIAGRAM
Figure 7-1. Circuit Diagram For 250 DX Models
OM-363 Page 54
231 394-B
ENGLISH
Figure 7-2. Circuit Diagram For 350 LX Models
231 395-B
OM-363 Page 55
225 650-A
Figure 7-3. Circuit Diagram For Optional Cooler
OM-363 Page 56
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
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
OM-363 Page 57
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.
OM-363 Page 58
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.
gtaw_Phase_2010−03
!
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 )
Amperage Range - Gas Type - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens
.040” (1 mm)
25-85
20-80
1/16” (1.6 mm)
50-160
50-150
3/32” (2.4 mm)
130-250
135-235
250-400
225-360
1/8” (3.2 mm)
Pure Tungsten (Green Band)
.040” (1 mm)
Pure Tungsten Not Recommended
10-60
1/16” (1.6 mm)
For DCEN − Argon
50-100
3/32” (2.4 mm)
100-160
1/8” (3.2 mm)
150-210
Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
9-2. Preparing Tungsten Electrode For Welding With Phase Control Machines
!
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding
2-1/2 Times
Electrode Diameter
Radial Grinding
Causes Wandering Arc
1
3
2
1
Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
2
Tungsten Electrode
A 2% ceriated tungsten is recommended.
4
Wrong Tungsten Preparation
Ideal Tungsten Preparation − Stable Arc
3
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
B. Preparing Tungsten For AC Welding
1
Tungsten Electrode
A pure tungsten is recommended..
1 − 1-1/2 Times
Electrode Diameter
1
2
2
Balled End
Ball end of tungsten by applying AC amperage recommended for a given electrode
diameter (see Section 9-1). Let ball on end of
the tungsten take its own shape.
OM-363 Page 59
ENGLISH
SECTION 9 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING
SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW)
2007−04
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
1
Make sure workpiece is clean
before welding.
2
Work Clamp
Place as close to the weld as
possible.
10−15
4
5
6
10−25
3
4
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare
according to Section 9.
tungsten
Guidelines:
5
6
1/16 in
3/16 in
Bottom View Of Gas Cup
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
The tungsten extension should be
no greater than the inside diameter
of the gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
OM-363 Page 60
ENGLISH
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
Tilt torch
Remove rod
15
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
OM-363 Page 61
10-3. Positioning Torch Tungsten For Various Weld Joints
90
Butt Weld And Stringer Bead
70
20
20
“T” Joint
70
10
20
40
Lap Joint
70
20
30
90
Corner Joint
70
20
ST-162 003 / S-0792
OM-363 Page 62
ENGLISH
Notes
OM-363 Page 63
SECTION 11 − PARTS LIST
Hardware is common and
not available unless listed.
350 LX Model Illustrated
54
4
55
63
70
16
23
103
91
20
25
26
89
12
112
104
41
14
15
49
104
21
22
19
48
18
28
Figure 11-1. Main Assembly
OM-363 Page 64
ENGLISH
350 LX Model Illustrated
40
87
104
43
109
108
65
44
59
39
11
42
34
37
33
38
96
35
95
97
83
3
111
5
104
7
8
13
46
6
10
52
53
90
78
9
80
75
1
73
58
2
82
72
97
78
76
104
1
803 804-M
OM-363 Page 65
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 11-1. Main Assembly
Quantity
Model
250 350
DX
LX
. . . 1 . . . . . . . . . . 211 038 . . BASE, ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 1 . . . . . . . . . . 233 120 . . BASE, ASSY FACTORY OPTION FOR USE W/ CS COOLER . . . . . . . . . 1 . . .
. . . 2 . . . . . . . . . . 215 656 . . END CAP, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . .
. . . 3 . . T1/Z1 . 212 555 . . XFMR/STABILIZER ASSY, 200/230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . T1/Z1 . 211 041 . . XFMR/STABILIZER ASSY, 230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . T1/Z1 . 219 652 . . XFMR/STABILIZER ASSY, 220/400/440/520 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . T1/Z1 . 215 767 . . XFMR/STABILIZER ASSY, 200/230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . T1/Z1 . 215 389 . . XFMR/STABILIZER ASSY, 230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . T1/Z1 . 217 801 . . XFMR/STABILIZER ASSY, 220/400/440/520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . TH1 . . 201 443 . . THERMISTOR,NTC 10K OHM @ 25 DEG C 27.5IN LEAD . . . . . . . . . . . 1 . . .
. . . 4 . . . . . . . . . . 212 550 . . PANEL, LEFT WINDTUNNEL (for non-TIGRUNNER models) . . . . . . . . . . 1 . . .
. . . 5 . . . TE1 . . 224 127 . . TERM ASSY, PRI 1PH 3V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 6 . . . . . . . . . . 213 248 . . LUG, UNIV W/SCREW 2/0−14 WIRE .266STD . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 7 . . C5, 6 . 111 634 . . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 8 . . . SR1 . . 212 558 . . RECTIFIER, SCR MAIN (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . . . . . . . . . . . . . . 218 581 . . . . THYRISTOR, SCR 300A 300V HOCKEY PUCK . . . . . . . . . . . . . . . . . . . 4 . . .
. . . . . . . . . TH2 . . 218 580 . . THERMISTOR,NTC 30K OHM @ 25 DEG C 40IN LEAD . . . . . . . . . . . . . 1 . . .
. . . 9 . . . . . . . . . . 218 670 . . BRACKET, RECTIFIER RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 10 . . . . . . . . . . 212 559 . . BRACKET, RECTIFIER LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 11 . . . . R3 . . 186 949 . . RESISTOR, WW FXD 175 W 20 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 12 . . . . S5 . . 207 236 . . SWITCH ASSY, POLARITY (DX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 13 . . . . . . . . . +213 105 . . PANEL, RIGHT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 14 . . . . S1 . . 246 694 . . SWITCH, TGL ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 15 . . . . . . . . . . 231 281 . . FRONT PANEL ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . . . . . . . . . . . . . . 117 860 . . BLANK, SNAP−IN NYL .187 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . . . . . . . . . . . . . . 107 983 . . BLANK, SNAP−IN NYL .500 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . . . . . . . . . . . . . . 143 397 . . BLANK, SNAP−IN NYL .312 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . 8 . . .
. . . 16 . . . PC1 . . 231 300 . . CIRCUIT CARD ASSY, CONTROL & INTERFACE W/PROGRAM . . . . . . . . . . . . 1 . . .
. . . 16 . . . PC1 . . 237 547 . . CIRCUIT CARD ASSY, CONTROL & INTERFACE W/PROGRAM (CE) . . . . . . . . 1 . . .
. . . 18 . . . . . . . . . . 183 332 . . KNOB, POINTER .570 DIA X .125 ID W/SPRING CLIP . . . . . . . . . . . . . . . 2 . . .
. . . 19 . . . . . . . . . . 174 991 . . KNOB, POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . 1 . . .
. . . 20 . . . . . . . . . . 195 778 . . ACTUATOR PUSH BUTTON ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 21 . . . . . . Figure 11-2 . . PANEL,LOWER DINSE CONN ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 22 . . . C14 . . 209 587 . . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 23 . . . PC2300 548 . . KIT PULSER (INCLUDES), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . PC2 . . 300 548 . . KIT PULSER (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 237 545 . . . . CIRCUIT CARD, PULSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . . . . . . . . . . . . . . 183 332 . . . . KNOB, POINTER .570 DIA X .125 ID W/SPRING CLIP . . . . . . . . . . . . . 3 . . .
. . . . . . . . . . . . . . . . 195 778 . . . . ACTUATOR, PUSH BUTTON ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . . . . . . . . . . . . . . 190 512 . . . . STAND-OFF, NO.6-32 X .640 LG .250 HEX AL FEM . . . . . . . . . . . . . . . 1 . . .
. . . 25 . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, UPPER (ORDER BY MODEL AND SERIAL NUMBER) . . 1 . . .
. . . 26 . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, LOWER (ORDER BY MODEL AND SERIAL NUMBER) . . 1 . . .
. . . 28 . . . . . . . . . . 175 952 . . PLASTIC, HANDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . . . . . . . . . . . . . . 169 136 . . PIN, HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 33 . . . . . . . . . . 231 283 . . PANEL, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 34 . . . . . . . . . . 184 058 . . FAN, PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 35 . . . . . . . . . . 187 807 . . BRACKET, MTG MOTOR FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . .
. . . 37 . . . . . . . . . . 150 783 . . BLADE, FAN 9.000 5WG 39DEG .312 BORE CW PLSTC . . . . . . . . . . . . . 2 . . .
. . . 38 . . FM1, 2 220 393 . . MOTOR, FAN 230V 50/60HZ 1550 RPM .312 DIA SHAFT . . . . . . . . . . . . 2 . . .
. . . 39 . . . . 1T . . 199 312 . . BLOCK, TERMINAL FAST−ON,20 AMP, 250 VOLT . . . . . . . . . . . . . . . . . . 1 . . .
. . . 40 . . . GS1 . . 238 805 . . VALVE, 24 VDC 2WAY,125 PSI CUSTOM PORT.054 ORF W/FRICTION 1 . . .
. . . 41 . . . . . . . . . . 231 279 . . FITTING, GAS−CLIP MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . . . . . . . . . . . . . . 217 111 . . PLUG, PROTECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . .
. . . 42 . . . . . . . . . . 235 413 . . SUPPORT, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . 235 412 . . SUPPORT, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . 218 280 . . HINGE, CONT POLYOLEFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 44 . . . . . . . . . +215 657 . . DOOR, ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 44 . . . . . . . . . +229 068 . . DOOR, ACCESS VENTED (FOR MODELS W/COOLERS ONLY) . . . . . . 1 . . .
. . . 46 . . . . . . . . . . 217 553 . . LABEL,GROUND/PROTECTIVE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
OM-363 Page 66
1
1
4
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
8
1
1
5
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
2
2
2
1
1
1
2
1
1
1
1
1
Dia.
Mkgs.
Part
No.
Description
Figure 11-1. Main Assembly (continued)
Quantity
Model
250 350
DX
LX
. . . 48 . . . . T4 . . 215 771 . . COIL, HF COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 49 . . . . . . . . . . 207 560 . . INSULATOR, STANDOFF WITH STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 52 . . . . . . . . . . 211 043 . . PANEL, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 53 . . . . . . . . . . 199 479 . . LABEL, MILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 54 . . . . . . . . . . 232 914 . . SEAL ,LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 55 . . . . . . . . . +232 910 . . COVER, TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 58 . . . . . . . . . . 208 294 . . CONNECTOR, FASTON MALE 4−PRONG . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2
. . . 59 . . . . . . . . . . 010 467 . . CONN, CLAMP CABLE 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 63 . . . . . . . . . . 203 990 . . LABEL, WARNING GENERAL PRECAUTIONARY STATIC
. . . . . . . . . . . . . . . . . . . . . . . . . . . (200/230/460 VOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 63 . . . . . . . . . . 217 136 . . LABEL, WARNING ELECTRIC SHOCK (ENG/FR)
. . . . . . . . . . . . . . . . . . . . . . . . . . . (230/460/575 VOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 65 . . . . . . . . . . 179 310 . . LABEL,GENERAL PRECAUTIONARY WORDLESS INTL SMALL
. . . . . . . . . . . . . . . . . . . . . . . . . . . (220/400/440/520 VOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 65 . . . . . . . . . . 218 598 . . LABEL,WARNING ELECTRIC SHOCK AND INCORRECT INPUT P
. . . . . . . . . . . . . . . . . . . . . . . . . . . (200/230/460 VOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 65 . . . . . . . . . . 219 332 . . LABEL, WARNING ELECTRIC SHOCK AND INCORRECT ENG/FR
. . . . . . . . . . . . . . . . . . . . . . . . . . . (230/460/575 VOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 65 . . . . . . . . . . 220 401 . . LABEL,WARNING ELECTRIC SHOCK INPUT CONNECTION CE W
. . . . . . . . . . . . . . . . . . . . . . . . . . . (220/400/440/520 VOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 70 . . . . . . . . . . 232 912 . . DRAWER, ASSY (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 213 111 . . . . DRAWER, PLASTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 232 911 . . . . DRAWER, FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 217 255 . . . . SLIDE, DRAWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . 72 . . . . T3 . . 219 927 . . XFMR, HIGH VOLTAGE 115V PRI 3600V SEC 34 MA W/TERM . . . . . . . 1 . . . 1
. . . 73 . . . . G1 . . 231 258 . . SPARK GAP ASSY, (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 231 259 . . . . BASE, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 231 260 . . . . HOLDER, POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3
. . . . . . . . . . . . . . . . 221 736 . . . . POINTS, SPARK GAP (DUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 221 737 . . . . POINTS, SPARK GAP (SINGLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . . . . . . . . . . . . . . 231 261 . . . . BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . 3
. . . 75 . . . . R8 . . 188 067 . . RESISTOR, WW FXD 100 W 200 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 76 . . . . C3 . . 239 528 . . CAPACITOR, MICA .002 UF 10000 V PANEL MTG W/LEADS . . . . . . . . . 1 . . . 1
. . . 78 . C11, 19 195 552 . . CAPACITOR, POLYP MET FILM 20. UF 250 VAC 10% . . . . . . . . . . . . . . . 2 . . . 2
. . . 80 . . . . R1 . . 220 808 . . RESISTOR, WW FXD 100 W 50 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 82 . . . C13 . . 206 878 . . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 83 . . . . . . . . . . 216 081 . . BRACKET, RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 87 . . . . . . . . . . 218 170 . . HOSE, NPRN BRD NO 1 X .250 ID X 24.000 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 89 . . . . . . . . . . 211 039 . . BEZEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 90 . . . . . . . . . . 224 459 . . LABEL, WARNING HF GAPS/ELECT SHOCK/CE/WORDLESS
. . . . . . . . . . . . . . . . . . . . . . . . . . . (220/400/440/520 VOLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 91 . . . HD1 . . 191 941 . . TRANSDUCER, CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 95 . . . . C2 . . 031 668 . . CAPACITOR, ELCTLT 4000 UF 100 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 96 . . . . . . . . . . 108 105 . . CLAMP, CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 97 . . R2, 4 . 118 459 . . RESISTOR, WW FXD 10 W 1K OHM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . 103 . . PC3300 547 . . KIT SEQUENCER (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 239 373 . . . . CIRCUIT CARD, SEQUENCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 183 332 . . . . KNOB, POINTER .570 DIA X .125 ID W/SPRING CLIP . . . . . . . . . . . . . 5 . . . 5
. . 104 . . . . Figure 11-3 . . TIGRUNNER RUNNING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . 108 . . CR2 . . 059 266 . . RELAY, ENCL 120VAC DPDT 10A/120VAC 8PIN . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . 194 744 . . RFCS−14HD (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . 109 . . . . . . . . . 222 451 . . BRACKET, RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . 110 . . . . . . . . . 137761 . . NUT, 750 NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . 111 . . . . . . . . . 035 704 . . RECTIFIER, INTEG BRIDGE 40. AMP 800V . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . 112 . . . . . . . . . 230 155 . . BRACKET, VALVE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
Part of TIGRUNNER option.
Field option only.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-363 Page 67
ENGLISH
Item
No.
12
Hardware is common and
not available unless listed.
11
10
3
12
10
11
5
14
9
1
13
8
14
9
2
13
8
803 775-A
Figure 11-2. Panel, Lower Dinse Connector Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
220 509
...
...
...
...
...
...
...
...
...
...
...
1
2
3
5
8
9
10
11
12
13
14
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
213 109
218 784
224 529
218 174
202 553
185 712
185 713
229 338
185 717
186 228
185 718
..
..
..
..
..
..
..
..
..
..
..
Quantity
Figure 11-2. Panel, Lower Dinse Connector Assy (Figure 11-1 Item 21)
PANEL, LOWER DINSE CONN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN, CIRC MS/CPC 14SKT SIZE 20 RCPT W/FILTERING . . . . . . . . . . . . .
RECEPTACLE, W/LEADS & CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, TWIST LOCK BRASS POWER (FEMALE) . . . . . . . . . . . . . . .
INSULATOR, BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR, BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, DOMED LOAD .812 ID X 1.450 OD X .070 THK . . . . . . . . . . . . . .
NUT, M20−1.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . .
O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
2
2
2
2
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-363 Page 68
ENGLISH
Hardware is common and
4
not available unless listed.
3
2
13
12
12
5
9
6
8
11
7
10
Ref. 803 725-D
Figure 11-3. Optional Running Gear
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Running Gear (Optional) (Figure 11-1 Item 104)
. . . 2 . . . . . . . . . +215 928 . .
. . . 3 . . . . . . . . . . 168 663 . .
. . . 4 . . . . . . . . . . 602 387 . .
. . . 5 . . . . . . . . . . 191 158 . .
. . . 6 . . . . . . . . . . 121 614 . .
. . . 7 . . . . . . . . . . 602 250 . .
. . . 8 . . . . . . . . . . 209 869 . .
. . . 9 . . . . . . . . . . 191 167 . .
. . . 10 . . . . . . . . . . 168 247 . .
. . . 11 . . . . . . . . . . 191 163 . .
. . . 12 . . . . . . . . . . 242 337 . .
. . . 13 . . . . . . . . . . 217 140 . .
...........................
. . . 13 . . . . . . . . . . 200 285 . .
...........................
BOTTLE SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOOK SPRING SNAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOTTLE TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,FLAT .812IDX1.469ODX.134T STL PLD ANSI.750 . . . . . . . . . . . .
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CASTER, SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CASTER MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE, UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING CYL MAY EXPLODE IF DAMAGED (ENG/FR)
(230/460/575 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING CYLINDER MAY EXPLODE IF DAMAGED
(200/230/460 VOLT MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
2
1
2
4
2
1
2
1
2
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-363 Page 69
SECTION 12 − PARTS LIST FOR OPTIONAL COOLER
Hardware is common and
not available unless listed.
1
2
3
4
26
25
5
28
7
30
27
24
23
22
6
8
9
7
29
21
20
19
18
17
10
16
14
11
15
12
13
804 995-A
Figure 12-1. Main Assembly
OM-363 Page 70
7
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
. . . 1 . . . . . . . . . . 213 072
. . . 2 . . . . . . . . . . 231 341
. . . 3 . . . . . . . . . . 232 424
. . . 4 . . . . . . . . . . 232 842
. . . 5 . . . . . . . . . . 232 609
. . . 6 . . . . . . . . . . 200 109
. . . 7 . . . . . . . . . . 231 400
. . . 8 . . . . . . . . . . 174 042
. . . 9 . . . . . . . . . . . . . 5523
. . . 10 . . . . . . . . . . 134 795
. . . 11 . . . . . . . . . . 023 562
. . . 12 . . . . . . . . . . 173 263
. . . 13 . . . . . . . . . . 231 337
. . . 14 . . . . . . . . . . 232 413
. . . 15 . . . . . . . . . . 231 340
. . . 16 . . . . . . . . . . 204 604
. . . 17 . . . . . . . . . . 149 356
. . . 18 . . . . . . . . . . 204 603
. . . . . . . . . . . . . . . . 226 934
. . . 19 . . . . . . . . . . 186 005
. . . 20 . . . . . . . . . . 166 566
. . . 21 . . . . . . . . . . 226 936
. . . 22 . . . . . . . . . . 226 935
. . . 23 . . . . . . . . . . 233 159
. . . 24 . . . . . . . . . . 178 461
. . . 25 . . . . . . . . . . 139 042
. . . 26 . . . . . . . . . . 188 082
. . . 27 . . . . . . . . . . 232 621
. . . 28 . . . . . . . . . . 231 339
. . . 29 . . . . . . . . . . 166 564
. . . . . . . . . . . . . . . . 225 113
. . . . . . . . . . . . . . . . 141 727
. . . 30 . . . . . . . . . . 166 608
. . Fan, Muffin 115 V 60 Hz 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . .
. . Plenum, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Radiator, Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Rubber Braided .375 ID X .650 OD X 28.000 . . . . . . . . . . . . . . . . . . .
. . Hose, Rubber Braided .375 ID X .650 OD X 31.000 . . . . . . . . . . . . . . . . . . .
. . Tank, Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Rubber Braided .375 ID X .650 OD X 17.000 . . . . . . . . . . . . . . . . . . .
. . Pump, Coolant (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . FTG, Hose Brs Barbed Elbow M 3/8 TBG X 3/8 NPT . . . . . . . . . . . . . . .
. . . Coupler, Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Hose .312 − .875 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, 1/4 Hp 115 VAC 50/60 Hz 1425/1725 RPM Dual . . . . . . . . . . . . . . . .
. . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Rating Card CSA C US (Less Stock/Serial No) . . . . . . . . . . . . . . . . .
. . Panel, Front Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Coolant In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Hose Brs Barbed Elbow M Bhd 3/8 Tbg X .500−20 . . . . . . . . . . . . . . .
. . Label, Coolant Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Indicator, Flow (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lense, Flow Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . O−Ring, 1.301 ID X .070 CS 70 Duro Buna−n . . . . . . . . . . . . . . . . . . . . . .
. . . Paddle, Rotor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Housing, Flow Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Nylon .312 OD X .194 ID X .500 Lg . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Strain Relief .270/.470 ID X .804 mtg Hole . . . . . . . . . . . . . . . . . .
. . Cable, Power 2 Ft 7 In 16 ga 3c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tube, Pick−Up Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Front Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, In−line Low Profile 100 Screen 3/8 Hose Bar . . . . . . . . . . . . . . . . . . .
. . Harness, 3CS Cooler (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Tubing, Gl Acryl .750− .786 ID 4.000 Yel Fa1 (Not Shown) . . . . . . . . . . . . .
. . Cap, Tank Screw−On W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
1
3
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-363 Page 71
Notes
Effective January 1, 2010
(Equipment with a serial number preface of MA or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions 6. 90 Days — Parts
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its
* Accessory (Kits)
original retail purchaser that new Miller equipment sold after the
* Canvas Covers
effective date of this limited warranty is free of defects in material
* Induction Heating Coils and Blankets, Cables, and
and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* M-Guns
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* MIG Guns and Subarc (SAW) Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
* Replacement Parts (No labor)
any warranted parts or components that fail due to such defects in
* Roughneck Guns
material or workmanship. Miller must be notified in writing within
* Spoolmate Spoolguns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to an
International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or
for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Work Stations/Weld Tables (No Labor)
6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)
Miller’s True Blue Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4) payment
of or credit for the purchase price (less reasonable depreciation
based upon actual use) upon return of the goods at customer’s risk
and expense. Miller’s option of repair or replacement will be F.O.B.,
Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized
service facility as determined by Miller. Therefore no
compensation or reimbursement for transportation costs of any
kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS
EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.
miller_warr 2010−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
 2010 Miller Electric Mfg. Co.
2010−01
Download PDF