Miller INVERTER RACK (NSPR 11014) Owner’s Manual

PDF
Document
OM-196 919
August 1999
Processes
Multiprocess Welding
Description
Inverter Rack
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding equip- figure out what the problem is. The parts list
ment manufacturer in the U.S.A. will then help you to decide which exact part
to be registered to the ISO 9001
you may need to fix the problem. Warranty and
Quality System Standard.
service information for your particular model
are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
Working as hard as you do −
every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage &agrave; l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers suppl&eacute;mentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de s&eacute;curit&eacute; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs &eacute;lectromagn&eacute;tiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Installing Welding Power Source Onto Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Common Work Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Paralleling Welding Power Sources For SMAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − MAINTENANCE &amp; TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
OM-196 919
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable − do not use work clamp or work cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-196 919 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-196 919 Page 2
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-196 919 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-196 919 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT
UTILISATION
som _nd_fre 5/97
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette proc&eacute;dure
pr&eacute;sente des risques de danger ! Ceux-ci sont identifi&eacute;s
par des symboles adjacents aux directives.
Y Identifie un message de s&eacute;curit&eacute; particulier.
. Signifie NOTA ; n’est pas relatif &agrave; la s&eacute;curit&eacute;.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reli&eacute;s aux CHOCS &Eacute;LECTRIQUES, aux PI&Egrave;CES EN
MOUVEMENT et aux PI&Egrave;CES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de conna&icirc;tre les mesures &agrave; prendre pour
&eacute;viter tout danger.
1-2. Dangers relatifs au soudage &agrave; l’arc
Y Les symboles pr&eacute;sent&eacute;s ci-apr&egrave;s sont utilis&eacute;s tout au long du
pr&eacute;sent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionn&eacute;es afin d’&eacute;viter tout danger. Les
consignes de s&eacute;curit&eacute; pr&eacute;sent&eacute;es ci-apr&egrave;s ne font que r&eacute;sumer
l’information contenue dans les normes de s&eacute;curit&eacute; &eacute;num&eacute;r&eacute;es
&agrave; la section 1-4. Veuillez lire et respecter toutes ces normes de
s&eacute;curit&eacute;.
Y L’installation, l’utilisation, l’entretien et les r&eacute;parations ne doivent &ecirc;tre confi&eacute;s qu’&agrave; des personnes qualifi&eacute;es.
Y Au cours de l’utilisation, tenir toute personne &agrave; l’&eacute;cart et plus particuli&egrave;rement les enfants.
D Ne pas toucher l’&eacute;lectrode quand on est en contact avec la pi&egrave;ce, la
terre ou une &eacute;lectrode provenant d’une autre machine.
D N’utiliser qu’un mat&eacute;riel en bon &eacute;tat. R&eacute;parer ou remplacer sur-lechamp les pi&egrave;ces endommag&eacute;es. Entretenir l’appareil conform&eacute;ment
&agrave; ce manuel.
D Porter un harnais de s&eacute;curit&eacute; quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le c&acirc;ble de retour de fa&ccedil;on &agrave; obtenir un bon contact m&eacute;tal-m&eacute;tal
avec la pi&egrave;ce &agrave; souder ou la table de travail, le plus pr&egrave;s possible de la
soudure.
D
UN CHOC &Eacute;LECTRIQUE peut tuer.
Un simple contact avec des pi&egrave;ces &eacute;lectriques peut
provoquer une &eacute;lectrocution ou des blessures graves.
L’&eacute;lectrode et le circuit de soudage sont sous tension
d&egrave;s que l’appareil est sur ON. Le circuit d’entr&eacute;e et les
circuits internes de l’appareil sont &eacute;galement sous
tension &agrave; ce moment-l&agrave;. En soudage semi-automatique ou automatique,
le fil, le d&eacute;vidoir, le logement des galets d’entra&icirc;nement et les pi&egrave;ces
m&eacute;talliques en contact avec le fil de soudage sont sous tension. Des
mat&eacute;riels mal install&eacute;s ou mal mis &agrave; la terre pr&eacute;sentent un danger.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs apr&egrave;s la suppression de l’alimentation &eacute;lectrique.
D Arr&ecirc;ter les convertisseurs, d&eacute;brancher le courant &eacute;lectrique, et d&eacute;charger les condensateurs d’alimentation selon les instructions
indiqu&eacute;es dans la partie entretien avant de toucher les pi&egrave;ces.
D Ne jamais toucher les pi&egrave;ces &eacute;lectriques sous tension.
D Porter des gants et des v&ecirc;tements de protection secs ne comportant
pas de trous.
D S’isoler de la pi&egrave;ce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour emp&ecirc;cher le contact physique &eacute;ventuel avec la pi&egrave;ce ou la terre.
D
D
D
Ne pas se servir de source &eacute;lectrique &agrave;courant &eacute;lectrique dans les zones
humides, dans les endroits confin&eacute;s ou l&agrave; o&ugrave; on risque de tomber.
Se servir d’une source &eacute;lectrique &agrave;courant &eacute;lectrique UNIQUEMENT si le
proc&eacute;d&eacute; de soudage le demande.
Si l’utilisation d’une source &eacute;lectrique &agrave;courant &eacute;lectrique s’av&egrave;re n&eacute;cessaire, se servir de la fonction de t&eacute;l&eacute;commande si l’appareil en est &eacute;quip&eacute;.
D Couper l’alimentation ou arr&ecirc;ter le moteur avant de proc&eacute;der &agrave; l’installation, &agrave; la r&eacute;paration ou &agrave; l’entretien de l’appareil. D&eacute;verrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
s&eacute;curit&eacute;).
D Installer et mettre &agrave; la terre correctement cet appareil conform&eacute;ment &agrave;
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours v&eacute;rifier la terre du cordon d’alimentation − V&eacute;rifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccord&eacute; &agrave; la
borne de terre du sectionneur ou que la fiche du cordon est raccord&eacute;e
&agrave; une prise correctement mise &agrave; la terre.
D En effectuant les raccordements d’entr&eacute;e fixer d’abord le conducteur
de mise &agrave; la terre appropri&eacute; et contre-v&eacute;rifier les connexions.
D V&eacute;rifier fr&eacute;quemment le cordon d’alimentation pour voir s’il n’est pas
endommag&eacute; ou d&eacute;nud&eacute; − remplacer le cordon imm&eacute;diatement s’il est
endommag&eacute; − un c&acirc;ble d&eacute;nud&eacute; peut provoquer une &eacute;lectrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser des c&acirc;bles us&eacute;s, endommag&eacute;s, de grosseur insuffisante ou mal &eacute;piss&eacute;s.
D Ne pas enrouler les c&acirc;bles autour du corps.
D Si la pi&egrave;ce soud&eacute;e doit &ecirc;tre mise &agrave; la terre, le faire directement avec un
c&acirc;ble distinct − ne pas utiliser le connecteur de pi&egrave;ce ou le c&acirc;ble de
retour.
Isoler la pince de masse quand pas mis &agrave; la pi&egrave;ce pour &eacute;viter le contact
avec tout objet m&eacute;tallique.
LES FUM&Eacute;ES ET LES GAZ peuvent
&ecirc;tre dangereux.
Le soudage g&eacute;n&egrave;re des fum&eacute;es et des gaz. Leur
inhalation peut &ecirc;tre dangereux pour votre sant&eacute;.
D
D
D
D
D
D
D Eloigner votre t&ecirc;te des fum&eacute;es. Ne pas respirer
les fum&eacute;es.
A l’int&eacute;rieur, ventiler la zone et/ou utiliser un &eacute;chappement au niveau
de l’arc pour l’&eacute;vacuation des fum&eacute;es et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur &agrave; alimentation d’air homologu&eacute;.
Lire les sp&eacute;cifications de s&eacute;curit&eacute; des mat&eacute;riaux (MSDSs) et les
instructions du fabricant concernant les m&eacute;taux, les consommables, les rev&ecirc;tements, les nettoyants et les d&eacute;graisseurs.
Travailler dans un espace ferm&eacute; seulement s’il est bien ventil&eacute; ou en
portant un respirateur &agrave; alimentation d’air. Demander toujours &agrave; un
surveillant d&ucirc;ment form&eacute; de se tenir &agrave; proximit&eacute;. Des fum&eacute;es et des
gaz de soudage peuvent d&eacute;placer l’air et abaisser le niveau d’oxyg&egrave;ne provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne pr&eacute;sente aucun danger.
Ne pas souder dans des endroits situ&eacute;s &agrave; proximit&eacute; d’op&eacute;rations de
d&eacute;graissage, de nettoyage ou de pulv&eacute;risation. La chaleur et les
rayons de l’arc peuvent r&eacute;agir en pr&eacute;sence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des m&eacute;taux munis d’un rev&ecirc;tement, tels que l’acier
galvanis&eacute;, plaqu&eacute; en plomb ou au cadmium &agrave; moins que le rev&ecirc;tement n’ait &eacute;t&eacute; enlev&eacute; dans la zone de soudure, que l’endroit soit bien
ventil&eacute;, et si n&eacute;cessaire, en portant un respirateur &agrave; alimentation
d’air. Les rev&ecirc;tements et tous les m&eacute;taux renfermant ces &eacute;l&eacute;ments
peuvent d&eacute;gager des fum&eacute;es toxiques en cas de soudage.
OM-196 919 Page 5
LES RAYONS DE L’ARC peuvent provoquer des br&ucirc;lures dans les yeux et
sur la peau.
Le rayonnement de l’arc du proc&eacute;d&eacute; de soudage
g&eacute;n&egrave;re des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des br&ucirc;lures dans les yeux et sur la peau. Des &eacute;tincelles sont projet&eacute;es
pendant le soudage.
D Porter un casque de soudage muni d’un &eacute;cran de filtre appropri&eacute; pour
prot&eacute;ger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 &eacute;num&eacute;r&eacute; dans les normes de s&eacute;curit&eacute;).
D Porter des protections approuv&eacute;s pour les oreilles si le niveau sondre est
trop &eacute;lev&eacute;.
D Utiliser des &eacute;crans ou des barri&egrave;res pour prot&eacute;ger des tiers de l’&eacute;clair
et de l’&eacute;blouissement; demander aux autres personnes de ne pas regarder l’arc.
D Porter des v&ecirc;tements de protection constitu&eacute; dans une mati&egrave;re durable, r&eacute;sistant au feu (cuir ou laine) et une protection des pieds.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectu&eacute; sur des conteneurs ferm&eacute;s tels
que des r&eacute;servoirs, tambours ou des conduites peut
provoquer leur &eacute;clatement. Des &eacute;tincelles peuvent &ecirc;tre
projet&eacute;es de l’arc de soudure. La projection d’&eacute;tincelles, des pi&egrave;ces chaudes et des &eacute;quipements chauds peut provoquer des
incendies et des br&ucirc;lures. Le contact accidentel de l’&eacute;lectrode avec des
objets m&eacute;talliques peut provoquer des &eacute;tincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, v&eacute;rifier
et s’assurer que l’endroit ne pr&eacute;sente pas de danger.
D Se prot&eacute;ger et d’autres personnes de la projection d’&eacute;tincelles et de
m&eacute;tal chaud.
D Ne pas souder dans un endroit l&agrave; o&ugrave; des &eacute;tincelles peuvent tomber sur
des substances inflammables.
D D&eacute;placer toutes les substances inflammables &agrave; une distance de 10,7
m de l’arc de soudage. En cas d’impossibilit&eacute; les recouvrir soigneusement avec des protections homologu&eacute;s.
D Des &eacute;tincelles et des mat&eacute;riaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
D Surveiller tout d&eacute;clenchement d’incendie et tenir un extincteur &agrave; proximit&eacute;.
D Le soudage effectu&eacute; sur un plafond, plancher, paroi ou s&eacute;paration
peut d&eacute;clencher un incendie de l’autre c&ocirc;t&eacute;.
D Ne pas effectuer le soudage sur des conteneurs ferm&eacute;s tels que des
r&eacute;servoirs, tambours, ou conduites, &agrave; moins qu’ils n’aient &eacute;t&eacute; pr&eacute;par&eacute;s correctement conform&eacute;ment &agrave; AWS F4.1 (voir les normes de
s&eacute;curit&eacute;).
D Brancher le c&acirc;ble sur la pi&egrave;ce le plus pr&egrave;s possible de la zone de soudage pour &eacute;viter le transport du courant sur une longue distance par
des chemins inconnus &eacute;ventuels en provoquant des risques d’&eacute;lectrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour d&eacute;geler des conduites gel&eacute;es.
D En cas de non utilisation, enlever la baguette d’&eacute;lectrode du porte&eacute;lectrode ou couper le fil &agrave; la pointe de contact.
D Porter des v&ecirc;tements de protection d&eacute;pourvus d’huile tels que des
gants en cuir, une chemise en mat&eacute;riau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D Le soudage, l’&eacute;caillement, le passage de la pi&egrave;ce
&agrave; la brosse en fil de fer, et le meulage g&eacute;n&egrave;rent
des &eacute;tincelles et des particules m&eacute;talliques volantes. Pendant la p&eacute;riode de refroidissement des soudures, elles risquent de projeter du laitier.
D
Porter des lunettes de s&eacute;curit&eacute; avec &eacute;crans lat&eacute;raux ou un &eacute;cran facial.
OM-196 919 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
m&ecirc;me la mort.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours &agrave; bien a&eacute;rer les espaces confin&eacute;s ou se servir d’un respirateur d’adduction d’air homologu&eacute;.
D
D
DES PI&Egrave;CES CHAUDES peuvent provoquer des br&ucirc;lures graves.
D Ne pas toucher des parties chaudes &agrave; mains nues
D Pr&eacute;voir une p&eacute;riode de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGN&Eacute;TIQUES peuvent
affecter les stimulateurs cardiaques.
D
D
Porteurs de stimulateur cardiaque, restez &agrave; distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur m&eacute;decin avant de s’approcher
des op&eacute;rations de soudage &agrave; l’arc, de gougeage ou
de soudage par points.
LE BRUIT peut affecter l’ou&iuml;e.
Le bruit des processus et des &eacute;quipements peut affecter
l’ou&iuml;e.
D
Porter des protections approuv&eacute;s pour les oreilles si
le niveau sondre est trop &eacute;lev&eacute;.
Si des BOUTEILLES sont endommag&eacute;es, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommag&eacute;e, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du proc&eacute;d&eacute; de soudage, les
manipuler avec pr&eacute;caution.
D Prot&eacute;ger les bouteilles de gaz comprim&eacute; d’une chaleur excessive,
des chocs m&eacute;caniques, du laitier, des flammes ouvertes, des &eacute;tincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les emp&ecirc;cher de tomber ou de
se renverser.
D Tenir les bouteilles &eacute;loign&eacute;es des circuits de soudage ou autres circuits &eacute;lectriques.
D Ne jamais placer une torche de soudage sur une bouteille &agrave; gaz.
D Une &eacute;lectrode de soudage ne doit jamais entrer en contact avec une
bouteille.
D Ne jamais souder une bouteille pressuris&eacute;e − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, r&eacute;gulateurs,
tuyaux et raccords convenables pour cette application sp&eacute;cifique;
les maintenir ainsi que les &eacute;l&eacute;ments associ&eacute;s en bon &eacute;tat.
D Ne pas tenir la t&ecirc;te en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.
D Lire et suivre les instructions concernant les bouteilles de gaz comprim&eacute;, les &eacute;quipements associ&eacute;s et les publications P-1 CGA &eacute;num&eacute;r&eacute;es dans les normes de s&eacute;curit&eacute;.
1-3. Dangers suppl&eacute;mentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou &agrave; proximit&eacute; de surfaces infllammables.
D Rester &agrave; l’&eacute;cart des organes mobiles comme le
ventilateur.
D Maintenir ferm&eacute;s et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil &agrave; proximit&eacute; de produits inflammables
D Ne pas surcharger l’installation &eacute;lectrique − s”assurer que l’alimentation est correctement dimensionn&eacute; et prot&eacute;g&eacute; avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FR&Eacute;QUENCE (H.F.) risque de provoquer
des interf&eacute;rences.
LA CHUTE DE L’APPAREIL peut
blesser.
D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un engin d’une capacit&eacute; appropri&eacute;e pour
soulever l’appareil.
D En utilisant des fourches de levage pour d&eacute;placer l’unit&eacute;, s’assurer
que les fourches sont suffisamment longues pour d&eacute;passer du c&ocirc;t&eacute;
oppos&eacute; de l’appareil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’&Eacute;QUIPEMENT.
D
D
D
D
D
D Pr&eacute;voir une p&eacute;riode de refroidissement, respecter le cycle op&eacute;ratoire nominal.
D R&eacute;duire le courant ou le cycle op&eacute;ratoire avant de
recommancer le soudage.
LE SOUDAGE &Agrave; L’ARC risque de
provoquer des interf&eacute;rences.
D Ne pas obstruer les passages d’air du poste.
LES CHARGES &Eacute;LECTROSTATIQUES peuvent endommager les circuits imprim&eacute;s.
D &Eacute;tablir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pi&egrave;ces.
D Utiliser des pochettes et des bo&icirc;tes antistatiques
pour stocker, d&eacute;placer ou exp&eacute;dier des cartes de
circuits imprimes.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
D Ne pas appuyer sur la gachette avant d’en avoir
re&ccedil;u l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pi&egrave;ce m&eacute;canique en engageant le fil
de soudage.
D Le rayonnement haute frequence peut provoquer
des interf&eacute;rences avec les &eacute;quipements de radio−navigation et de communication, les services
de s&eacute;curit&eacute; et les ordinateurs.
Demander seulement &agrave; des personnes qualifi&eacute;es familiaris&eacute;es
avec des &eacute;quipements &eacute;lectroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un &eacute;lectricien
qualifi&eacute; les interf&eacute;rences r&eacute;sultant de l’installation.
Si le FCC signale des interf&eacute;rences, arr&ecirc;ter imm&eacute;diatement l’appareil.
Effectuer r&eacute;guli&egrave;rement le contr&ocirc;le et l’entretien de l’installation.
Maintenir soigneusement ferm&eacute;s les portes et les panneaux des
sources de haute fr&eacute;quence, maintenir les &eacute;clateurs &agrave; une distance
correcte et utiliser une terre et et un blindage pour r&eacute;duire les interf&eacute;rences &eacute;ventuelles.
D
D
D
D
D
D L’&eacute;nergie &eacute;lectromagn&eacute;tique risque de provoquer
des interf&eacute;rences pour l’&eacute;quipement &eacute;lectronique
sensible tel que les ordinateurs et l’&eacute;quipement
command&eacute; par ordinateur tel que les robots.
Veiller &agrave; ce que tout l’&eacute;quipement de la zone de soudage soit compatible &eacute;lectromagn&eacute;tiquement.
Pour r&eacute;duire la possibilit&eacute; d’interf&eacute;rence, maintenir les c&acirc;bles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller &agrave; souder &agrave; une distance de 100 m&egrave;tres de tout &eacute;quipement
&eacute;lectronique sensible.
Veiller &agrave; ce que ce poste de soudage soit pos&eacute; et mis &agrave; la terre
conform&eacute;ment &agrave; ce mode d’emploi.
En cas d’interf&eacute;rences apr&egrave;s avoir pris les mesures pr&eacute;c&eacute;dentes, il
incombe &agrave; l’utilisateur de prendre des mesures suppl&eacute;mentaires telles que le d&eacute;placement du poste, l’utilisation de c&acirc;bles blind&eacute;s, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGN&Eacute;TIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez &agrave; distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur m&eacute;decin avant de s’approcher des op&eacute;rations de soudage &agrave; l’arc, de gougeage ou de soudage par points.
OM-196 919 Page 7
1-4. Principales normes de s&eacute;curit&eacute;
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
R&egrave;gles de s&eacute;curit&eacute; en soudage, coupage et proc&eacute;d&eacute;s connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs &eacute;lectromagn&eacute;tiques
Donn&eacute;es sur le soudage &eacute;lectrique et sur les effets, pour l’organisme,
des champs magn&eacute;tiques basse fr&eacute;quence
Afin de r&eacute;duire les champs &eacute;lectromagn&eacute;tiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les c&acirc;bles de soudage, causera des champs &eacute;lectromagn&eacute;tiques. Il y a eu et il y a encore
un certain souci &agrave; propos de tels champs. Cependant, apr&egrave;s avoir examin&eacute; plus de 500 &eacute;tudes qui ont &eacute;t&eacute; faites pendant une p&eacute;riode de
recherche de 17 ans, un comit&eacute; sp&eacute;cial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comit&eacute;, n’a pas d&eacute;montr&eacute; que l’exposition aux champs
magn&eacute;tiques et champs &eacute;lectriques &agrave; haute fr&eacute;quence repr&eacute;sente un
risque &agrave; la sant&eacute; humaine”. Toutefois, des &eacute;tudes sont toujours en cours
et les preuves continuent &agrave; &ecirc;tre examin&eacute;es. En attendant que les conclusions finales de la recherche soient &eacute;tablies, il vous serait
souhaitable de r&eacute;duire votre exposition aux champs &eacute;lectromagn&eacute;tiques pendant le soudage ou le coupage.
OM-196 919 Page 8
2
3
4
5
Garder les c&acirc;bles ensembles en les torsadant ou en les
attachant avec du ruban adh&eacute;sif.
Mettre tous les c&acirc;bles du c&ocirc;t&eacute; oppos&eacute; de l’op&eacute;rateur.
Ne pas courber pas et ne pas entourer pas les c&acirc;bles autour de
votre corps.
Garder le poste de soudage et les c&acirc;bles le plus loin possible de
vous.
Relier la pince de masse le plus pr&egrave;s possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous &ecirc;tes d&eacute;clar&eacute; apte par votre docteur, il est
alors recommand&eacute; de respecter les consignes ci−dessus.
SECTION 2 − INSTALLATION
2-1. Selecting A Location
Dimensions And Weight
256 lb (116 kg)
7 ft (2.1 m)
minimum length
7 ft (2.1 m)
minimum length
59-3/8 in
(1508 mm)
43 in
(1092 mm)
Movement
34-3/8 in
(873 mm)
1
1
Lifting Eyes
Use lifting eye to move unit.
2
Lifting Forks
If using lifting forks, be sure forks
are fully inserted.
2
loc_2 3/96 - ST-801 697
OM-196 919 Page 9
2-2. Installing Welding Power Source Onto Rack
1
2
1 Welding Power Source
Position welding power source onto rack shelf so holes in base of
welding power source are over holes in shelf. Welding power source
front panel should face side of rack with isolated terminal on base
as shown.
2
Securing Bolts And Hardware
Install user-supplied 1/4-inch mounting hardware through rack shelf
into welding power source and tighten.
ST-801 192 / ST-801 696 / ST-801 698
OM-196 919 Page 10
2-3. Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 − 60%
Duty Cycle
60 − 100%
Duty Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
700
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
800
4/0
2-2/0
2-3/0
2-4/0
3-4/0
3-4/0
4-4/0
4-4/0
900
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
1000
2-2/0
2-3/0
2-4/0
3-3/0
4-3/0
4-4/0
1250
2-3/0
2-4/0
3-3/0
4-3/0
4-4/0
1500
2-4/0
3-3/0
3-4/0
4-4/0
10 − 100% Duty Cycle
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
S-0007-D
OM-196 919 Page 11
2-4. Common Work Connections
1
3
5
3
4
4
5
2
ST-801 700
Y Turn Off welding power sources by
placing Power circuit breakers in the
Off position before making any weld
output connections.
Y Do not connect welding output of different polarities to the same structure.
Y See ANSI Z49.1 and OSHA Title 29,
Chapter XVII, Part 1910, Subpart Q
(addresses at beginning of manual).
Y Do not handle or come in contact with
two live electrodes at the same time.
Y ARCING can burn skin or damage
electrical equipment. Do not change
position of the welding cable connectors while welding.
Y Be sure the connectors are secure in
receptacles before welding.
OM-196 919 Page 12
Y INADEQUATE WORK CABLE CONNECTIONS can cause serious damage to input power service and create
a hazardous condition. Connect an
electrical cable of adequate size between the isolated terminal and the
workpiece whenever the isolated terminal is used.
1
Positive (+) Weld Output Cables
Determine cable lengths and sizes according to welding power source Owner’s
Manual.
2
Isolated Terminal
3
Negative (−) Weld Output Cables
Determine cable sizes according to welding
power source Owner’s Manual. Cable must
reach from negative (−) output receptacle to
isolated terminal.
4
Common Negative (−) Weld Output
Cable
Cable must be able to carry combined weld
output of all welding power sources using
common work connections. Use Section 2-3
to select proper cable size.
5
Terminal Lugs
Use lugs of proper amperage capacity and
hole size for connecting to isolated terminal.
Isolated terminal is 1/2 in (12.7 mm) in
diameter.
For Electrode Negative, reverse cable connections. Positive (+) weld output cables
connect to isolated terminal, negative (−)
weld output cables go to electrode. Common
weld output cable is positive.
2-5. Paralleling Welding Power Sources For SMAW
1
1
4
4
2
1
Securely cover connection
with proper insulating
material.
3
4
ST-801 701
Y Turn Off welding power sources by
placing Power circuit breakers in the
Off position before making any weld
output connections.
Y Do not connect welding output of different polarities to the same
structure.
Y See ANSI Z49.1 and OSHA Title 29,
Chapter XVII, Part 1910, Subpart Q
(addresses at beginning of manual).
Y Do not handle or come in contact with
two live electrodes at the same time.
Y UNDERSIZED WELDING CABLES
can cause fire. Use single cables of
adequate capacity to carry the total
combined amperage of the paralleled
welding power sources
Y ARCING can burn skin or damage
electrical equipment. Do not change
position of the welding cable connectors while welding.
Y Be sure the connectors are secure in
receptacles before welding.
Y INADEQUATE WORK CABLE CONNECTIONS can cause serious damage to input power service and create
a hazardous condition. Connect an
electrical cable of adequate size between the isolated terminal and the
workpiece whenever the isolated terminal is used.
Set the Amperage/Voltage control on all paralleled welding power sources to the same
value. The isolated terminal may be used as
a common connection point if no other connections are made to it.
The procedure shown is for Electrode Positive welding connections.
1 Weld Output Cables
Determine cable sizes according to welding
power source Owner’s Manual. Cables must
reach cable connection point. Cables connected together must be the same polarity.
2 Connection Point
Cover with proper insulating material after
making connections.
3 Terminal Lugs
Use lugs of proper amperage capacity and
hole size for connection.
4 Common Weld Output Cable
Cable must be able to carry combined weld
output of all welding power sources connected in parallel. Use Section 2-3 to select
proper cable size.
For Electrode Negative, reverse cable connections. Positive (+) weld output cables connect to work, negative (−) weld output cables
go to electrode.
OM-196 919 Page 13
SECTION 3 − MAINTENANCE &amp; TROUBLESHOOTING
3-1. Routine Maintenance
. Maintain more often
Y Disconnect power
before maintaining.
during severe conditions.
3 Months
Replace
Damaged Or
Unreadable
Labels
Repair Or
Replace
Cracked
Cables
Replace Cracked
Torch Body
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
Clean And
Tighten Connections
To Isolated Terminal
OM-196 919 Page 14
Effective January 1, 1999
(Equipment with a serial number preface of KK&quot; 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
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts − 3 Years Labor
*
*
2.
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
3 Years — Parts and Labor
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
*
*
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
*
*
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
Motor Driven Guns (w/exception of Spoolmate
185)
*
*
Process Controllers
Positioners and Controllers
*
*
Automatic Motion Devices
Robots
*
*
RFCS Foot Controls
IHPS Power Sources
*
*
*
Water Coolant Systems
HF Units
Grids
*
*
Maxstar 140
Spot Welders
*
*
Load Banks
SDX Transformers
*
*
Miller Cyclomatic Equipment
Running Gear/Trailers
*
Plasma Cutting Torches (except APT, ZIPCUT &amp;
PLAZCUT Models)
*
Field Options
(NOTE: Field options are covered under True
Blue&reg; for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
*
APT, ZIPCUT &amp; PLAZCUT Model Plasma Cutting
Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate 185
Miller’s True Blue&reg; Limited Warranty shall not apply to:
1.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
2.
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
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 7/99
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
To locate distributor nearest you call
1-800-4-A-Miller.
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA &amp; Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
File a claim for loss or damage during
shipment.
&copy; 1999 Miller Electric Mfg. Co.
7/99
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