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OM-2240 207688Z 2009−08 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description 115/230/400/460 Volt Models W/AutolineR Arc Welding Power Source Dynasty 200 SD And DX R (Including Optional Cart And Cooler) 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 figure out what the problem is. The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001:2000 Quality Warranty and service information for your System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Mil_Thank 4/05 Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 7 2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4-3. DC Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4-4. AC Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4-6. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4-7. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4-8. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4-9. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4-10. TIG HF Impulse/ Lift-Arct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4-11. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4-12. TIGRunner Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4-13. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4-14. Connecting Three-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4-15. Connecting Single-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5-2. Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5-3. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5-4. Ammeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5-5. Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5-6. Polarity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5-7. Lift-Arc And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5-8. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5-9. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5-10. Pulser Control (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5-11. Sequencer Controls (DX And CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5-12. Adjust Controls (Preflow/Post Flow/DIG/Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5-13. AC Waveshape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5-14. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control On The Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5-16. Factory Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 5-17. Resetting Unit To Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SECTION 6 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6-1. Programmable TIG Start, And Preset Amperage Minimum Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 36 TABLE OF CONTENTS 6-2. AC Waveshape Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 6-3. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6-4. Arc Timer/Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6-5. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 6-6. Setting Unit To Display PPP While Pulse Welding (DX Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 6-7. Stick Open-Circuit Voltage (OCV) Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 6-8. Stick Stuck Check Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 SECTION 7 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 7-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SECTION 9 − HIGH FREQUENCY (HF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 9-2. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 10-1. Typical GTAW Set-Ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 11-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . . 68 11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 SECTION 12 − GUIDELINES FOR (GTAW) TIG WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 12-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 12-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 12-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 SECTION 13 − SETUP GUIDE FOR (SMAW) STICK WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . . 71 SECTION 14 − GUIDELINES FOR (SMAW) STICK WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 14-1. Electrode and Amperage Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 14-2. Stick Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 14-3. Striking an Arc − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 14-4. Striking an Arc − Tapping Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 14-5. Positioning Electrode Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 14-6. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 14-7. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 14-8. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 14-9. Electrode Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 14-10. Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 14-11. Lap Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 14-12. Tee Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 14-13. Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 14-14. Troubleshooting − Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 14-15. Troubleshooting − Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 14-16. Troubleshooting − Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 14-17. Troubleshooting − Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 14-18. Troubleshooting − Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 14-19. Troubleshooting − Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 14-20. Troubleshooting − Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 14-21. Troubleshooting − Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 SECTION 15 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 SECTION 16 − COOLER PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 SECTION 17 − CART PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2009−08 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. D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. D Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. D When making input connections, attach proper grounding conductor first − double-check connections. D Keep cords dry, free of oil and grease, and protected from hot metal and sparks. D Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill. D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly with a separate cable. D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D Do not connect more than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower. D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. HOT PARTS can burn. D Do not touch hot parts bare handed. D Allow cooling period before working on equipment. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. OM-2240 Page 1 FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. D After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. D Use only correct fuses or circuit breakers. Do not oversize or bypass them. D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. FLYING METAL or DIRT can injure eyes. D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. D Wear approved safety glasses with side shields even under your welding helmet. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator. ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet. D Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. D Wear 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. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). D Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. D Do not use welder to thaw frozen pipes. OM-2240 Page 2 ELECTRIC AND MAGNETIC FIELDS (EMF) can affect ImplantedMedical Devices. D Wearers of Pacemakers and other Implanted Medical Devices should keep away. D Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. D Wear approved ear protection if noise level is high. CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder − explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. D Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment. MOVING PARTS can injure. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place. D Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. D Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power. READ INSTRUCTIONS. D Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. D Use only genuine replacement parts from the manufacturer. D Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. OVERUSE can cause OVERHEATING H.F. RADIATION can cause interference. D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit. FLYING SPARKS can injure. D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. D Sparks can cause fires — keep flammables away. D D D D STATIC (ESD) can damage PC boards. D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards. ARC WELDING can cause interference. MOVING PARTS can injure. D Keep away from moving parts. D Keep away from pinch points such as drive rolls. WELDING WIRE can injure. D Do not press gun trigger until instructed to do so. D Do not point gun toward any part of the body, other people, or any metal when threading welding wire. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. D D D D D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. OM-2240 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. 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-2240 Page 4 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended. SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2009−07 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. NOTE − Indique des déclarations pas en relation avec des blessures personnelles. . Indique des instructions spécifiques. Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger. 2-2. Dangers relatifs au soudage à l’arc Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité. Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil. Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil. UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort. Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger. D Ne pas toucher aux pièces électriques sous tension. D Porter des gants isolants et des vêtements de protection secs et sans trous. D S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol. D Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande. D Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul ! D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes nationales, provinciales et locales. D Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. D Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes. D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu peut entraîner la mort. D L’équipement doit être hors tension lorsqu’il n’est pas utilisé. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés. D Ne pas enrouler les câbles autour du corps. D Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. D Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. D Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée. D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel. D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. D S’assurer que tous les panneaux et couvercles sont correctement en place. D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. D Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. OM-2240 Page 5 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement. D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. D Eloigner votre tête des fumées. Ne pas respirer les fumées. D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé. D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. D Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués. D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables. D Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud. D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité. D Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. D Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité). D Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs. D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple). D Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger. D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. D Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. D Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intense (ultraviolets et infrarouges) susceptibles de provoquer des brûlure dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). D Porter des lunettes de sécurité avec écrans latéraux même sous votre casque. D Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc. OM-2240 Page 6 D Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie. D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact. D Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau 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. D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. D Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. D Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux. D Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS peuvent affecter médicaux. MAGNETIQUES des implants D Porteur de simulateur cardiaque ou autre implants médicaux, rester à distance. D Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. LE BRUIT peut endommager l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. D Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé. LES BOUTEILLES peuvent exploser si elles sont endommagées. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. D Ne jamais souder une bouteille pressurisée − risque d’explosion. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état. D Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille. D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur. D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles. D Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité. 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures. D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire. D Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. D Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur. D Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal. D Réduire le courant ou le facteur de marche avant de poursuivre le soudage. D Ne pas obstruer les passages d’air du poste. LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures. D Porter un écran facial pour protéger le visage et les yeux. D Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps. D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable. LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes. OM-2240 Page 7 Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. 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 gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. Les PIÈCES MOBILES peuvent causer des blessures. D S’abstenir de toucher des organes mobiles tels que des ventilateurs. D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié. D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique. LIRE LES INSTRUCTIONS. D Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. D N’utiliser que les pièces de rechange recommandées par le constructeur. D Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs. D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. D Si le FCC signale des interférences, arrêter immédiatement l’appareil. D Effectuer régulièrement le contrôle et l’entretien de l’installation. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles. LE SOUDAGE À L’ARC risque de provoquer des interférences. D D D D D D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots. Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. 2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants) Les batteries, les bornes et autres accessoires contiennent du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation. OM-2240 Page 8 Pour les moteurs à essence : Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Pour les moteurs diesel : Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations congénitales ou autres problèmes de procréation. 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com). National Electrical Code, NFPA Standard 70, de National Fire Protection Association, Quincy, MA 02269 (téléphone : 800-344-3555, site Internet : www.nfpa.org et www.sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet : www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone : 800-463-6727, site internet : www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, site Internet : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : 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, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site Internet : www.osha.gov). U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site internet : 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 (télé[hone : 1-800-232-4636, site internet: www.cdc.gov/NIOSH). 2-6. Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques. Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ». Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage. Pour réduire les champs magnétiques sur le poste de travail, appliquer les procédures suivantes : 1. Garder les câbles ensemble, les torsader, les scotcher, ou les recouvrir d’une housse. 2. Disposer les câbles d’un côté et à distance de l’opérateur. 3. Ne pas courber et ne pas entourer les câbles autour de votre corps. 4. Garder le poste de soudage et les câbles le plus loin possible de vous. 5. Connecter la pince sur la pièce aussi près que possible de la soudure. En ce qui concerne les implants médicaux : Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes. OM-2240 Page 9 OM-2240 Page 10 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperes Panel−Local V Volts Voltage Input Voltage Output Circuit Breaker Remote Protective Earth (Ground) Postflow Timer Preflow Timer On Off Positive Alternating Current Gas Input Gas Output Duty Cycle Direct Current Line Connection X U1 U0 Hz Primary Voltage IP Degree Of Protection Gas Tungsten Arc Welding (GTAW) Shielded Metal Arc Welding (SMAW) 3 Phase Static Frequency Converter-Transformer-Rectifier I1max Rated Maximum Supply Current Lift-Arc Start (GTAW) S Seconds Negative I2 U2 I1eff Rated Welding Current Conventional Load Voltage Maximum Effective Supply Current Rated No Load Voltage (Average) Pulse Background Amperage Initial Amperage Increase/Decrease Of Quantity Normal Trigger Operation (GTAW) Two-Step Trigger Operation (GTAW) Four-Step Trigger Operation (GTAW) Percent Hertz Recall From Memory Arc Force (DIG) HF Impulse Starting (GTAW) Final Slope Final Amperage Pulse Percent On Time Initial Slope Contactor Control (Stick) Pulser On-Off TIG Weld Amps And Peak Amps While Pulsing Pulse Frequency Background Amps Process Pulser Sequence Output Adjust S Suitable For Areas Of Increased Shock Hazard OM-2240 Page 11 SECTION 4 − INSTALLATION 4-1. 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. 4-2. Specifications Input Power Rated Output Welding Amperage Range ** Max. Open-Circuit Voltage (Uo) 130 A @ 25.2 VDC, 60% Duty Cycle 1 − 200 150 A @ 16 VDC, 60% Duty Cycle 1 − 200 5-10♦ Three-Phase Stick Process 200 A @ 28 VDC, 20% Duty Cycle 1 − 200 5-10♦ Three-Phase TIG Process 200 A @ 18 VDC, 20% Duty Cycle 1 − 200 130 A @ 25.2 VDC, 60% Duty Cycle 1 − 200 Three-Phase Stick Process Three-Phase TIG Process Single-Phase Stick Process Single-Phase TIG Process Single-Phase Stick Process Single-Phase TIG Process Single-Phase Stick Process Single-Phase TIG Process 80∇ 5-10♦ Rated Peak Striking Voltage (Up) 15 KV*** Amperes Input At Rated Output, 50/60Hz -− 12.3 0.16* 7.6 0.24* 6.0 0.25* 9.4 6.0 4.7 3.8 3.6 -− 0.16* 0.24* 0.25* 0.06* 0.03* 15 KV*** 20.8 13.0 10.2 8.1 7.8 0.16* 0.24* 0.25* 0.06* 0.03* 13.7 8.7 6.9 5.5 5.2 0.16* 0.24* 0.25* 0.06* 0.03* -− 20.0 0.23* -− 10.0 4.7 0.05* 4.7 0.02* -− 0.23* 15 KV*** 80∇ 15 KV*** 80 150 A @ 16 VDC, 60% Duty Cycle 1 − 200 100 A @ 24 VDC, 60% Duty Cycle 1 − 200 5-10♦ 15 KV*** 31.3 0.42* -− 140 A @ 15.6 VDC, 40% Duty Cycle 1 − 200 80 15 KV*** 31.0 0.42* 15 KV*** 15 KV*** 5-10♦ 15 KV*** 80∇ 5-10♦ 80∇ 90 A @ 23.6 VDC, 100% Duty Cycle 1 − 200 100 A @ 14 VDC, 100% Duty Cycle 1 − 200 5-10♦ 80 5-10♦ 4.6 0.03* 460 80 5-10♦ 4.8 0.06* 400 80∇ 5-10♦ KW 230 80 15 KV*** KVA 115 15.8 .25* 7.9 3.6 3.6 .25* 0.05* 0.02* -− -− 3.6 0.05* 3.6 0.03* -− -− -− 3.6 3.5 0.05* 0.03* 27.6 0.42* -− -− -− 20.7 0.42* -− -− -− -− 3.2 3.2 0.05* 0.03* 2.3 2.3 0.05* 0.03* *While idling ** Welding range for AC output is 5−200 amperes *** Arc starting device is designed for manual guided operations. ♦Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected. ∇Normal open-circuit voltage (80 volts) is present while in Stick with normal open-circuit voltage selected. . Duty cycle limitations on units with 115 volt input power are due to the input power cord supplied with the unit. . This unit is equipped with Auto-Linet. The Auto-Line circuitry automatically connects to 120−460 VAC, single- or three-phase power without removing the cover to relink the power source. OM-2240 Page 12 4-3. DC Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. 115VAC Input; DC Output 140 Stick Max. 120 100 TIG Max. Volts * 80 60 40 Stick/TIG Min. DIG Max. 20 0 0 50 100 150 Amperes 200 250 230VAC Single Phase Input; DC Output 140 Stick Max. 120 Volts 100 TIG Max. * 80 60 40 Stick/TIG Min. 20 0 0 50 DIG Max. 100 150 200 250 Amperes 3 Phase Voltage Input; DC Output 140 Stick Max. 120 Volts 100 TIG Max. * 80 60 40 Stick/TIG Min. 20 0 0 50 Dig Max. 100 150 Amperes 200 250 *Amperage setting must be reduced to obtain currents less than highlighted data* point. 210 168-A OM-2240 Page 13 4-4. AC Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. 115VAC Input; AC Output 140 Stick Max. 120 100 TIG Max. Volts * 80 60 40 Stick/TIG Min. 20 0 0 50 100 150 Amperes 200 250 230VAC Single Phase Input; AC Output 140 Stick Max. Volts 120 100 TIG Max. * 80 60 40 Stick/TIG Min. 20 0 0 50 100 150 200 250 Amperes 3 Phase Voltage Input; AC Output 140 120 Stick Max. Volts 100 * 80 TIG Max. 60 40 Stick/TIG Min. 20 0 0 50 100 150 Amperes 200 250 *Amperage setting must be reduced to obtain currents less than highlighted data* point. OM-2240 Page 14 210 168 4-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops, a Help message is displayed (see Section 7-3), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. OUTPUT AMPERES 250 200 TIG TIG (115V INPUT) 150 NOTICE − Exceeding duty cycle can damage unit or gun and void warranty. STICK 100 STICK (115V INPUT) 50 0 10 20 30 40 50 60 70 80 90 100 % DUTY CYCLE 100%dutycycle Continuous Welding 90 A @ 100% Duty Cycle For 115 Volt Single-Phase Stick Process 100 A @ 100% Duty Cycle For 115 Volt Single-Phase TIG Process 6 Minutes Welding 4 Minutes Resting 130 A @ 60% Duty Cycle For Stick Process (Other Voltages) 150 A @ 60% Duty Cycle For TIG Process (Other Voltages) Overheating A or V 0 15 Minutes OR Reduce Duty Cycle 210 167 OM-2240 Page 15 4-6. Selecting A Location 1 Line Disconnect Device Locate unit near correct input power supply. Dimensions And Weight ! 48.5 lb (22.0 kg) Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 21 in. (533 mm) 13-3/8 in. (333 mm) 7-9/16 in. (192 mm) Location And Air flow 1 18 in. (460 mm) Clearance 18 in. (460 mm) Clearance 803 428-A OM-2240 Page 16 4-7. Weld Output Terminals And Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 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. Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding ! 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 150 ft (45 m) 200 ft (60 m) Welding Amperes*** 10 − 60% Duty Cycle 60 − 100% Duty Cycle 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) 10 − 100% Duty Cycle − Output Receptacles * This 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 ***Select weld cable size for pulsing application at peak amperage value. S-0007-E− OM-2240 Page 17 4-8. Remote 14 Receptacle Information Socket* A B K J I A Contactor control +15 volts DC. B Contact closure to A completes 15 volts DC contactor control circuit and enables output. C Output to remote control; +10 volts DC output to remote control. REMOTE OUTPUT CONTROL D Remote control circuit common. E 0 to +10 volts DC input command signal from remote control. A/V 15 VOLTS DC H C L N D M G E F OUTPUT CONTACTOR 803 428-A Socket Information F Current feedback; +1 volt DC per 100 amperes. AMPERAGE VOLTAGE H Voltage feedback; +1 volt DC per 10 volts output. GND G +15 volts DC GND CHASSIS K Chassis common. * The remaining socket es are not used. . If a remote hand control, like the RHC-14, is connected to the Remote 14 receptacle, some current value above min. must be set on the remote control before the Panel or Remote contactor is turned on. Failure to do so will cause current to be controlled by the panel control, and the remote hand control will not function. 4-9. Gas Connections 1 Gas Fitting Fittings have 5/8-18 right-hand threads (3/8-19 BSPP on CE units). 2 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 4 3 2 3 4 Regulator/Flowmeter Flow Adjust Typical flow rate is 15 cubic feet per hour (7.1 liters per minute). 1 Connect customer supplied gas hose between regulator/flowmeter and gas fitting on rear of unit. Tools Needed: 11/16, 1-1/8 in., (21, 29 mm) 802 452 OM-2240 Page 18 4-10. TIG HF Impulse/ Lift-Arct Connections ! Turn off power before making connections. 1 Electrode Weld Output Terminal Connect TIG torch to weld output terminal labeled Electrode. 2 Gas Out Connection Connect torch gas hose to gas out fitting. 3 Work Weld Output Terminal Connect work lead to weld output terminal labeled Work. 4 Remote 14 Receptacle Connect desired remote control to Remote 14 receptacle. 5 5 Gas In Connection Connect gas hose from gas supply to gas in fitting. 3 2 1 4 Tools Needed: 11/16 in., (21 mm) 803 430-a 4-11. Stick Connections ! Turn off power before making connections. 1 Electrode Weld Output Terminal Connect electrode holder to weld output terminal labeled Electrode. 2 Work Weld Output Terminal Connect work lead to weld output terminal labeled Work. 3 Remote 14 Receptacle If desired, connect remote control to Remote 14 receptacle (see Section 4-8). 2 3 1 803 429-a OM-2240 Page 19 4-12. TIGRunner Connections Cart and cooler are optional equipment. 1 2 Gas Cylinder Chains Secure gas cylinder to cart with chains. Connect gas hose to welding power source (see Section 4-9). Connect work lead and torch to welding power source (see Section 4-10). 3 1 Water-Out (To Torch) Connection Connect torch water-in (blue) hose to welding power source water-out connection. 4 5 Water-In (From Torch) Connection Connect torch water-out (red) hose to welding power source water-in connection. 6 5 2 4 3 115 Or 230 Volt AC Grounded Receptacle (Depending On Model) For 115 volt models, an individual branch circuit capable of carrying 15 amperes and protected by fuses or circuit breakers is recommended. Recommended fuse or circuit breaker size is 15 amperes. For 230 volt models, an individual branch circuit capable of carrying 10 amperes and protected by fuses or circuit breakers is recommended. Recommended fuse or circuit breaker size is 10 amperes. 6 Power Cord NOTICE − Do not cut plug from 115 volt cord and attempt to rewire for 230 volts, or do not cut plug from 230 volt cord and attempt to rewire for 115 volts. GTAW Or Where HF* Is Used Application Low Conductivity Coolant No. 043 810**; Distilled Or Deionized Water OK Above 32° F (0° C) Coolant *HF: High Frequency Current Tools Needed: 11/16 in., (21 mm for CE units) **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-2240 Page 20 805 338-A 4-13. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. . Actual input voltage should not fall below 103 volts AC or rise above 506 volts AC. If actual input voltage is outside this range, unit may not operate according to specifications. Single-Phase, 100% Duty Cycle Single-Phase, 60% Duty Cycle 115 230 230 400 460 28 20 12.3 7.6 6.0 Time Delay 2 30 25 15 8 6 Normal Operating 3 40 30 20 10 10 10 12 14 14 14 57 (17) 79 (24) 102 (31) 308 (94) 407 (124) 10 12 14 14 14 Input Voltage Input Amperes At Rated Output Three-Phase, 60% Duty Cycle Max Recommended Standard Fuse Rating In Amperes 1 Min Input Conductor Size In AWG 4 Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG 4 Reference: 2008 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. OM-2240 Page 21 4-14. Connecting Three-Phase Input Power 3 ! 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. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. = GND/PE Earth Ground 4 . The Auto-Line circuitry in this unit au- tomatically adapts the power source to the primary voltage being applied. Check input voltage available at site. This unit can be connected to any input power between 120 and 460 VAC without removing cover to relink the power source. 7 For Three-Phase Operation 1 2 2 3 4 5 6 L1 3 L2 L3 6 5 Input Power Cord. Disconnect Device (switch shown in the OFF position) Green Or Green/Yellow Grounding Conductor Disconnect Device Grounding Terminal Input Conductors (L1, L2 And L3) Disconnect Device Line Terminals Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1, L2, and L3 to disconnect device line terminals. 7 1 Overcurrent Protection Select type and size of overcurrent protection using Section 4-13 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. Tools Needed: 2/04 - Ref. 802 136-A / 803 428-A OM-2240 Page 22 4-15. Connecting Single-Phase Input Power 1 8 =GND/PE Earth Ground ! 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. ! Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. 10 . The Auto-Line circuitry in this unit au- tomatically adapts the power source to the primary voltage being applied. Check input voltage available at site. This unit can be connected to any input power between 120 and 460 VAC without removing cover to relink the power source. 7 9 L1 L2 1 1 3 2 3 1 6 4 5 2 3 6 5 4 Black And White Input Conductor (L1 And L2) Red Input Conductor Green Or Green/Yellow Grounding Conductor Insulation Sleeving Electrical Tape Insulate and isolate red conductor as shown. 6 Input Power Cord. 7 Disconnect Device (switch shown in the OFF position) 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1 and L2 to disconnect device line terminals. 10 Overcurrent Protection Select type and size of overcurrent protection using Section 4-13 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. Tools Needed: 2/04 - Ref. 802 136-A / 803 428-A OM-2240 Page 23 SECTION 5 − OPERATION 5-1. Controls 1 2 3 11 4 5 6 7 8 9 10 12 207 694-A / 802 452 . For all front panel switch pad controls: press switch pad to turn on light and enable function. 4 Polarity Control 8 Sequencer Controls (DX, LX And All CE Models) See Section 5-6. See Section 5-11. . Green on nameplate indicates a TIG func- 5 9 1 See Section 5-8. tion, Gray indicates a Stick function. Encoder Control Use encoder control in conjunction with applicable front panel function switch pads to change values for that function. See Section 5-2. 2 Ammeter And Parameter Display See Section 5-4. 3 Voltmeter See Section 5-5. OM-2240 Page 24 6 Process Controls Output Controls See Section 5-9. 7 Pulser Controls (DX And LX Models) See Section 5-10. Adjust Controls See Section 5-12. 10 AC Waveshape Control See Section 5-13. 11 Amperage And Spot Time Control For Amperage control, see Section 5-3. For Spot Time control, see Section 5-14. 12 Power Switch Use switch to turn unit On/Off. 5-2. Encoder Control 1 Encoder Control Use control in conjunction with applicable front panel function switch pad to set values for that function. 1 5-3. Amperage Control 1 2 3 3 2 1 A (Amperage Control) Encoder Control Ammeter See Section 5-16 for Amperage control range. Press Amperage switch pad and turn Encoder control to set weld amperage. Weld amperage setting is also peak amperage when Pulser function is active (see Section 5-10). Or 5-4. Ammeter And Parameter Display 1 1 Ammeter Displays actual amperage while welding. Meter also displays preset parameters for any of the following units of measure when they are active: amperage, time, percentage or frequency. The corresponding LED, located directly below the ammeter, will also illuminate. OM-2240 Page 25 5-5. Voltmeter 1 1 Volt Meter Displays output or open circuit voltage. If output is off, the voltmeter will display a series of three dashes (-−−). Open circuit voltage is displayed if power is on and output is available. 5-6. Polarity Control 1 Polarity Control Press switch pad until desired LED is illuminated. DC - Machine is set to DCEN (direct current electrode negative) for TIG welding, and to DCEP (direct current electrode positive) for Stick welding. 1 OM-2240 Page 26 AC - Use AC (alternating current) for TIG and Stick welding. 5-7. Lift-Arc And HF TIG Start Procedures Lift-Arc Start When Lift-Arct button light is On, start arc as follows: Lift-Arc Start Method 1 “Touch” 1−2 Seconds 2 1 TIG Electrode 2 Workpiece Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control. Hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. Arc is formed when electrode is lifted. 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: Do NOT Strike Like A Match! Lift-Arc is used for the DCEN or AC GTAW process when HF Start method is not permitted, or to replace the scratch method. HF Start When HF Start button light is On, start arc as follows: High frequency turns on to help start arc when output is enabled. High frequency turns off when arc is started, and turns on whenever arc is broken to help restart arc. Application: HF start is used for the DCEN GTAW process when a non-contact arc starting method is required. OM-2240 Page 27 5-8. Process Control 1 Process Control Press switch pad until desired process LED is illuminated: TIG HF Impulse - When selected, a pulsed HF (non-contact) (see Section 5-7) arc starting method is activated. This method can be used with either AC or DC TIG welding. Make connections according to Section 4-10. 1 TIG Lift-Arct - When selected, is an arc starting method in which the electrode must come in contact with the workpiece to initiate an arc (see Section 5-7). This method can be used with either AC or DC TIG welding. Make connections according to Section 4-10. Stick (SMAW) - This method can be used with either AC or DC Stick welding. Make connections according to Section 4-11. 5-9. Output Control 1 1 Output Control Press switch pad until desired parameter LED is illuminated. RMT STD (Remote Standard) Application: Use Remote Trigger (Standard) when the operator desires to use a foot pedal or finger amperage control (see Section 6-3A). . When a foot or finger remote cur- rent control is connected to the welding power source, initial amps, initial slope, final slope, and final amps are controlled at the re- OM-2240 Page 28 mote control, not at the welding power source. only trigger input is functional (see Section 6-3B). . If On/Off only type trigger is used, . This switch function can be recon- it must be a maintained switch. All Sequencer functions become active, and must be set by the operator. RMT 2T HOLD Application: Use Remote Trigger Hold (2T) when long extended welds are made. Remote Trigger Hold (2T) can help to reduce operator fatigue. If a foot or finger current control is connected to the welding power source, figured for 4T, 4T Momentary, Mini Logic, or Spot control See Section 6-3C) ON Output will energize two seconds after being selected. Application: Use Output On for Stick (SMAW) welding, or for Lift-Arc without the use of a remote control (see Section 6-3H). 5-10. Pulser Control (DX Models Only) 1 3 2 Pulser Control Pulsing is available only while using the TIG process, it cannot be selected if the Stick process (see Section 5-8) is active. Controls can be adjusted while welding. Press switch pad to enable pulser. ON - When illuminated, this LED indicates the pulser is on. Press switch pad until desired parameter LED is illuminated. To turn Pulser off, press and release switch pad until the On LED turns off. 2 3 Encoder Control Ammeter Turn encoder (see Section 5-2) to select appropriate value for active pulse parameter. Value selected is shown on the ammeter (see Section 5-4). Also, the ammeter LED for the corresponding unit of measure (%, A, s, Hz) of the active parameter will be illuminated. 1 See Section 5-16 for all Pulser parameter ranges. PPS (Pulses Per Second or Pulse Frequency) - Control is used to determine appearance of weld bead. PEAK t - The percentage of each pulse cycle that can be spent at the peak amperage level. 4 Percent (%) Peak Time Control Setting Balanced Pulsed Output Waveforms PPS (50%) Bkg Amp Peak Amp BKGND A (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 Pulsed Output Waveforms Example shows affect changing the Peak Time control has on the pulsed output waveform. . Peak amperage is set using the More Time At Peak Amperage (80%) Amperage control (see Section 5-3). Peak amperage is the highest welding amperage allowed to occur in the pulse cycle. Weld penetration varies directly with peak amperage. Application: More Time At Background Amperage (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. OM-2240 Page 29 5-11. Sequencer Controls (DX And CE Models) 1 3 2 Sequencer Control Sequencing is available only while using the TIG process, but is disabled if a remote foot or finger current control is connected to the Remote receptacle while in the RMT STD mode. Sequencer parameters cannot be selected if the Stick process (see Section 5-8) is active. Press switch pad until desired parameter LED is illuminated. 4 Or 2 3 Encoder Control Ammeter Turn encoder (see Section 5-2) to set appropriate value for active sequence parameter. Value selected is shown on the ammeter (see Section 5-4). Also, the ammeter LED for the corresponding unit of measure (A, S) of the active parameter will be illuminated. See Section 5-16 for all Sequencer parameter ranges. 1 INITIAL A (Initial Amperage) - Use control to select a starting amperage that is different from the weld amperage. Application: Initial Amperage can be used while GTAW welding to assist in preheating cold material prior to depositing filler material, or to ensure a soft start. INITIAL t (Initial Time)(LX Models Only) - Press control again and turn Encoder to select amount of time that is needed at the beginning of the weld. INITIAL SLOPE t (Initial Slope Time) Use control to select amount of time that it takes to slope up/ down from initial amperage to weld amperage. To disable, set to 0. 4 Amperage Switch Pad Weld Time (LX Models Only) Press Amperage switch pad twice. Set desired length of weld time. FINAL SLOPE t (Final Slope Time) - Use control to select amount of time that it takes to slope up/down from weld amperage to final amperage. To disable, set to 0. 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. FINAL A (Final Amperage) - Use control to select amperage to which weld amperage has sloped up/ down to. FINAL t (Final Time)(LX Models Only) - Press control again and turn Encoder to select amount of time that is needed at the end of the weld. OM-2240 Page 30 5-12. Adjust Controls (Preflow/Post Flow/DIG/Purge) 1 Adjust Press switch pad until desired function LED is illuminated. 3 2 3 2 Encoder Control Ammeter Turn encoder (see Section 5-2) to set appropriate value for active Adjust parameter. Value selected is shown on the ammeter (see Section 5-4). Also, the ammeter LED for the corresponding unit of measure (S, %) of the active parameter will be illuminated. See Section 5-16 for all Adjust parameter ranges. PREFLOW - If the TIG HF process is active (see Section 5-8) and Preflow is shown on the control panel, use control to set length of time gas flows before arc initiation. To set Preflow time for models that do not have Preflow Time control on the front panel, see Section 5-15. Application: Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starts. . Some features shown are not available on all models. 1 POST FLOW - If the TIG process is active (see Section 5-8), use control to set length of time gas flows after welding stops. Application: Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance. DIG - If the Stick process is active (see Section 5-8), use control to set amount of DIG. When set at 0, short-circuit amperage at low arc voltage is the same as normal welding amperage. When setting is increased, short-circuit amperage at low arc voltage increases. Application: Control helps arc starting or making vertical or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking while welding. PURGE - While in the TIG process (see Section 5-8), to activate the gas valve and start the purge function, push and hold the Adjust switch pad for the desired amount of purge time. To set from 1 to 50 seconds of additional purge time, continue to hold the Adjust switch pad while turning the encoder control. Factory default setting is 0. While Purge is active, (PUR) is shown in the left display, and purge time is shown in the right display. Pressing any front panel switch pad will end the purge time display, but gas will continue to flow until the preset time has timed out. Application: Purge is used to clear the shielding gas lines of contaminates. OM-2240 Page 31 5-13. AC Waveshape 1 2 3 3 AC Waveshape Encoder Control Ammeter Turn encoder (see Section 5-2) to set appropriate value for active AC Waveshape parameter. Value selected is shown on the ammeter (see Section 5-4). 2 See Section 5-16 for all AC Waveshape parameter ranges. Balance: AC Balance Control is enabled only if AC TIG process is selected. Use control to set percentage of time polarity is electrode negative. 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. Joint configuration, set-up, process variables, and oxide thickness may affect setting. 1 AC Frequency: AC Frequency Control is enabled only if AC Polarity process is selected. Use control to set AC frequency (cycles per second). Application: AC frequency controls bead width and directional control. As AC frequency decreases, weld bead/ puddle gets wider. As AC frequency increases, weld bead/puddle becomes narrower and the arc becomes more focused. Travel speed can increase as AC frequency increases. 5-14. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) 1 1 SPO Spot Time Meter Display Select Spot function according to Section 6-3C. 3 Or 2 3 Amperage Switch Pad Encoder Control Set spot parameters as follows: Press Amperage switch pad once (meter A LED turns on) and turn Encoder to set spot amperage. Press Amperage switch pad again, (meter S LED lights) and turn Encoder to set spot time (.1−25 seconds). Factory default setting is 1 second. 1.0 Application: To provide a timed weld. Used for tacking, and thin sheet joining. Or 2 OM-2240 Page 32 5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control On The Front Panel 4 SEL 0.2 2 1 And 3 Rear Panel 1 Process Control Pad 2 Adjust Control Pad 3 Power Switch To adjust preflow, turn power switch on, and then press the Process and Adjust switch pads before the software version clears the meters, and hold the switch pads until software version clears the meters. Upon power up as described, the TIG Impulse, Postflow, DIG, and meter S LED’s turn on, and the factory default setting [SEL] [0.2] will be displayed. 4 Encoder Control Turn encoder to select from 0 to 25 seconds of preflow. The value selected is displayed on the ammeter. Application: Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting. OM-2240 Page 33 5-16. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution PROCESS TIG HF Impulse TIG HF Impulse / TIG Lift / Stick * Stick OCV Low OCV Low OCV / Normal OCV *Stick Stuck Check ScI (On) ScI (On) / Sc0 (Off) OUTPUT RMT STD RMT STD / RMT 2T / ON *RMT 2T 2T RMT 2T can be reconfigured for: 2T / 4T / Mini Logic / 4T Momentary / Spot (see Section 6-3C) A MAIN / PEAK AC TIG 150 A 5 − 200 Amps AC STICK 110 A 5 − 200 Amps DC TIG 150 A 1 − 200 Amps DC STICK 110 A 1 − 200 Amps Spot Time 1.0 S 0.1 − 25.0 Seconds PULSER Off ON / OFF PPS 100 Hz Dual Range And Resolution 0.1 − 9.9 / 10 − 500 Hertz PEAK t 40% 5 − 95 Percent BKGND A 25% 5 − 95 Percent *Meter “PPP” Display −−− (Off) −−− (Off) / PPP (On) 20 A 5 − 200 Amps AC SEQUENCER INITIAL A 1 − 200 Amps DC INITIAL SLOPE t 0S 0.0 − 25.0 Seconds FINAL SLOPE t 0S 0.0 − 25.0 Seconds FINAL A 5A 5 − 200 Amps AC 1 − 200 Amps DC ADJUST *PREFLOW 0.2 S 0.0 − 25.0 Seconds POST FLOW 10.0 S 0.0 − 50.0 Seconds @ 0.2 Second Resolution DIG 30% 0 − 100 Percent *Waveform Soft Square Soft Square, Advance Square, Sine, Triangle BALANCE 75% 30 − 99 Percent FREQUENCY 120 Hz 20 − 250 Hertz AC WAVESHAPE OM-2240 Page 34 DYNASTY: DC: *Tungsten .094 GEN, .020, .040, .062, .094, .125 **Polarity EN EP / EN **Amperage 60 1 − 200 Amps **Time 1 1 − 200 Milliseconds **Start Slope Time 40 0 − 250 Milliseconds **Preset Amperage Minimum 3 1 − 20 Amps *Tungsten .094 GEN, .020, .040, .062, .094, .125 **Polarity EP EP / EN **Amperage 120 5 − 200 Amps **Time 20 1 − 200 Milliseconds **Start Slope Time 10 0 − 250 Milliseconds **Preset Amperage Minimum 5 5 − 20 Amps AC: * Parameter adjusted using a power up configuration only. **Parameter adjusted using tungsten GEN only. 5-17. Resetting Unit To Factory Default Settings 1 2 3 4 Process Switch Pad Output Switch Pad Adjust Switch Pad Power Switch To reset all welding power source functions to original factory settings, lockout feature must be off (see Section 6-5). Next turn power on, then press the Process, Output, and Adjust switch pads before the software version clears the meters, and hold the switch pads until software version clears the meters. 1 2 3 4 Rear Panel OM-2240 Page 35 SECTION 6 − ADVANCED FUNCTIONS 6-1. Programmable TIG Start, And Preset Amperage Minimum Parameters A. Accessing Programmable TIG Start Parameters 2 Or 4 1 3 5 And Rear Panel . The welding cycle can be executed while in programmable start mode. Before accessing programmable TIG Start Tungsten, Polarity, Amperage, Time modes, and Preset Amperage Minimum, be sure that all procedures and parameters are established. 1 Process Switch Pad 2 Amperage Switch Pad 3 Power Switch To access the programmable TIG Start OM-2240 Page 36 parameter screens, turn power on, and then press the Process and Amperage switch pads before the software version clears the meters. Hold switch pads until software version clears the meters and [tun] appears. 4 Polarity Switch Pad Press Polarity switch pad to select AC or DC (see Section 5-6). . Each memory location and each polarity (AC or DC) has its own set of start parameters. Press the Process switch pad to select the desired process, TIG HF Impulse or TIG Lift Arc, for your application (see Section 5-8). The parameter values are the same for both processes, and any changes made to the values in one process, are duplicated in the other process. 5 Output Switch Pad Press Output switch pad to select desired type of control (see Section 5-9). Proceed to Section B. To save changes and exit Advanced Functions, turn power off. B. Tungsten Selection 3 2 Eun 094 Or 1 Current (A) Start Amperage Preset Amperage Minimum Start Time Start Slope Time 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter Preset TIG Start Parameters Use Encoder control to select a tungsten size from the following: .020, .040, .062 (1/16 in.), .094 (3/32 in.), or .125 (1/8 in.) (.094 is the default). When one of the listed tungsten sizes is selected, the following TIG starting parameters are preset: Amperage, Start Time, Start Slope Time, and Preset Amperage Minimum. There are a separate set of parameters for AC and DC (to select polarity see Section D). If it is necessary or desired to manually set the TIG starting parameters, turn the encoder until GEN is displayed on the amps meter (see Section C). OM-2240 Page 37 C. Selecting GEN 1 2 3 2 1 GEN Or 3 If [GEn] is selected and displayed on the amps meter, the TIG starting parameters for a .094 tungsten are the default, and for AC polarity they are: Start Polarity = EP, Start Amperage = 120 A, Start Time = 20 ms, Start Slope Time = 10 ms, Preset Minimum Amps = 5 A. For DC polarity they are: Start Polarity = EN, Start Amperage = 60 A, Start Time = 1 ms, Start Slope Time = 40 ms, Preset Minimum Amps = 3 A. These parameters can be manually changed by pressing the Amperage switch pad to step through each adjustable parameter. To change parameters, see Sections D, E, F, G, and H. GEN Default AC TIG Start Parameter Relationships Current (A) Start Amperage 120 Amps Preset Amperage Minimum 5 Amps Start Time 20 ms Start Slope Time 10 ms GEN Default DC TIG Start Parameter Relationships Current (A) Start Amperage 60 Amps Preset Amperage Minimum 3 Amps Start Time 1 ms Start Slope Time 40 ms OM-2240 Page 38 Encoder Control Amps Meter Amperage Switch Pad D. Changing Programmable TIG Start Polarity 3 SeP 2 EOr Current (A) 1 Start Polarity E. 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter [EP] is displayed on meters, and can be adjusted (see Section 5-16) by turning the Encoder control. To change Start Amperage, proceed to Section E. To adjust TIG Start Polarity proceed as follows: Press Amperage switch pad. Switch pad LED turns on, and meter % LED turns on. The current Start Polarity, (SEL] [E-] or [SEL] Changing Programmable TIG Start Amperage 3 SEa 2 20 Or Current (A) 1 Start Amperage 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust TIG Start Amperage proceed as follows: Press Amperage switch pad. Switch pad LED turns on, and meter A LED turns on. The current Start Amperage is displayed on the amps meter, and can be adjusted (see Section 5-16) by turning the Encoder control. To change Start Time, proceed to Section F. OM-2240 Page 39 F. Changing Programmable Start Time 3 See 2 10 Or Current (A) 1 Start Time 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust Programmable Start Time pro- G. ceed as follows: meter, and can be adjusted by turning the Encoder control (see Section 5-16). Press Amperage switch pad, and meter S LED turns on. The current Start Time is displayed in milliseconds on the amps To change Start Slope Time, proceed to Section G. Changing Start Slope Time 3 Sts 2 20 Current (A) Or 1 Start Slope Time 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter OM-2240 Page 40 To adjust Start Slope Time proceed as follows: Press Amperage switch pad. Switch pad LED turns on, and meter S LED turns on. The Start Slope Time is displayed in milli- seconds on the amps meter, and can be adjusted (see Section 5-16) by turning the Encoder control. To change Preset Amperage Minimum, proceed to Section H. H. Changing Preset Amperage Minimum 3 PA_ 2 5 Or 1 Current (A) Preset Amperage Minimum 1 Amperage Switch Pad 2 Encoder Control 3 Amps Meter To adjust Preset Amperage Minimum proceed as follows: Press Amperage switch pad. Switch pad LED turns on, and meter A LED turns on. The Preset Minimum Amperage is displayed on the amps meter, and can be adjusted (see Section 5-16) by turning the Encoder control. The preset amperage minimum can be independently set for AC and DC. . Whatever amperage is selected as the preset amperage minimum, is the minimum amperage that the machine will provide in either AC or DC. OM-2240 Page 41 6-2. AC Waveshape Selection SEL 4 SS f 2 1 3 And Rear Panel = Soft Squarewave = Advanced Squarewave = Sine wave 1 2 3 Polarity Switch Pad AC Waveshape Switch Pad Power Switch To access the AC Waveshape selection screen, turn power on, and then press the Polarity and Waveshape switch pads before the software version clears the meters and [SEL] [ssq) appears. The AC, Balance and Frequency LED’s will light. OM-2240 Page 42 = Triangular wave 4 Encoder Use the Encoder to select between advanced squarewave [ASq], soft squarewave [ssq] (default), sine wave (Sin), or triangle wave (Tri). To save changes and exit, press torch trigger or turn power off. Application: Use advance squarewave when a more focused arc is required for better directional control. Use soft squarewave when a softer arc with a more fluid puddle is desired. Use sine wave to simulate a conventional power source. Use triangular waveshape when the effects of peak amperage with reduced overall heat input is required to help control distortion on thin materials. 6-3. Output Control And Trigger Functions A. Remote (Standard) Torch Trigger Operation Current (A) Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow P&H R R Maintained Switch Foot Or Finger Remote Control P&H = Push trigger and hold R = Release trigger. . When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope and final amps are controlled by the remote control, not by the welding power source. B. Remote 2T Torch Trigger Operation Current (A) Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow P&R P&R P&R = Push trigger and release. . If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode. OM-2240 Page 43 C. Reconfiguring RMT 2T HOLD For 2T, 3T, Spot, 4T, 4T Momentary, Or Mini Logic Control 4 SEL H-2 Or 1 2 3 And Rear Panel For RMT STD (Remote Standard), RMT 2T Hold (Remote 2T Hold), and On trigger operation, see Section 6-3A, B, and H. 1 Process Switch Pad 2 Output Switch Pad 3 Power Switch To access the RMT 2T HOLD reconfiOM-2240 Page 44 guration screen, turn power switch on and then press the Process and Output switch pads before the software version clears the meters. Hold the switch pads until software version clears the meters and [SEL] [H‐2], [SEL] [SPO], [SEL] [H‐4], [SEL] [H4L], (SEL) (H‐3), or [SEL] [H4E] appears. 4 Encoder Control Turn Encoder to change functions. Active function will be displayed on amperage (right) meter. 5 Meter Displays Meter displays for the different functions will be as shown. Press torch trigger or turn power Off to save setting. . After 2T has been reconfigured and one of the reconfigured functions is selected during normal operation, H-4, H4L, H4E, H‐3, or SPO will be displayed for 1 second as a reminder to the operator. SEL SEL H-2 SPO = 2T (See Section 6-3B for operation) = Spot (See Section 6-3G for operation) 5 SEL H-4 SEL H4L SEL H4E = 4T Momentary SEL H‐3 = = 4T (DX, LX and CE Models) (See Section 6-3D for operation) = Mini Logic (DX, LX and CE Models) (See Section 6-3E for operation) (DX, LX and CE Models) (See Section 6-3F for operation) 3T (DX, LX and CE Models) (See Section 6-3I for operation) OM-2240 Page 45 D. 4T Specific Trigger Method (DX And CE Models) 1 1 4T (Specific Trigger Operation) Sequencer is required to reconfigure for 4T. SEL Select 4T according to Section 6-3C. H-4 Torch trigger operation is as shown. = 4T 4T allows the operator to toggle between weld current and final current without breaking the arc. . When a remote switch is con- nected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source. Application: Use 4T trigger method when the functions of a remote current control are desired, but only a remote on/off control is available. Current (A) Torch Trigger Operation Main Amps Initial Slope Final Slope Initial Amps Final Amps Postflow Preflow P&H R P&H = Push and hold trigger R = Release trigger P&R = Push trigger and release in less than 3/4 seconds OM-2240 Page 46 P&R P&R P&H R E. Mini Logic Operation (DX And CE Models) 1 1 Mini Logic Meter Display Select Mini Logic according to Section 6-3C. Torch trigger operation is as shown. SEL H4L = While in mini logic, the operator may use the trigger on the remote device to toggle between initial slope or main amps and initial amps as illustrated. Mini Logic During Mini Logic, Final Amperage is not available. Final slope will always slope to minimum amperage and end the cycle. . When a remote switch is con- nected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source. Application: This ability to change current levels without either initial slope or final slope, gives the operator the opportunity to adjust filler metal without breaking the arc. Torch Trigger Operation Main Amps Final Slope Initial Slope * Initial Amps P&H R * * * Preflow Postflow P&R P&R P&R P&R P&R P&H P&H = Push and hold trigger R = Release trigger P&R = Push trigger and release in less than 3/4 seconds * = Arc can be extinguished at final slope rate at any time by pushing and holding trigger. OM-2240 Page 47 F. 4T Momentary Operation (DX And CE Models) 1 4T Momentary Meter Display Select 4T Momentary according to Section 6-3C. 4T Momentary torch trigger operation is as shown. 1 . When SEL H4E = a remote switch is connected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source. 4T Momentary Main 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. Current (A) Main Amps Initial Slope Final Slope Initial Amps * Postflow Preflow P&R P&R P&R P&R = Push and release trigger. * = Push and releasing during final slope will break the arc and go to postflow. . For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends OM-2240 Page 48 Final Amps P&R P&R G. Spot Control Operation 1 1 Spot Function Meter Display Select Spot function according to Section 6-3C. . While SEL SPO = in Spot Control, Sequencer settings will be ignored and will not be programmable. Spot . When a remote switch is con- nected to the welding power source, use the remote switch to control the weld cycle. Amperage is controlled by the welding power source. Torch trigger operation is as shown. Application: To provide a timed weld. Used for tacking, and thin sheet joining. Current (A) Timed Spot Weld Amps Preflow Push & Hold Trigger Postflow Release Trigger After Spot Time Is Done OM-2240 Page 49 H. On Trigger Operation Voltage (V) ON 2 Sec Current (A) Stick Touch Stick Electrode Lift Stick Electrode Current (A) Lift Main Amperage Initial Amperage Initial Slope Touch Current Touch Tungsten OM-2240 Page 50 Lift Tungsten Slightly Lift Tungsten 3T Specific Trigger Method (DX And CE Models) I. 1 SEL H‐3 Current (A) Remote Trigger Operation * * * A Preflow * * * * B Initial Amps /Initial Slope C Main Amps D Final Slope /Final Amps E Postflow * Arc can be extinguished at any time by pressing and releasing both initial and final switches, or by lifting the torch and breaking the arc. 1 3T (Specific Trigger Operation) Sequencer is required to reconfigure for 3T. 3T requires two independent momentarycontact switches. One will be designated initial switch, and it must be connected between Remote 14 receptacle pins A and B. The second will be designated as the final switch, and it must be connected between Remote 14 receptacle pins D and E. Select 3T according to Section 6-3C. Definitions: Initial slope rate is the rate of amperage change determined by the initial amperage, initial slope time, and main amperage. Final slope rate is the rate of amperage change determined by the main amperage, final slope time, and final amperage. Operation: A..Press and release initial switch within 3/4 second to start shielding gas flow. To stop the preflow sequence before preflow time elapses (25 seconds), press and release final switch. The preflow timer will reset and the weld sequence can be started again. . If an initial switch closure is not made again before preflow time ends, gas flow stops, the timer resets, and an initial switch press and release is necessary to start the weld sequence again. B..Press initial switch to start arc at initial amps. Holding switch will change amperage at initial slope rate (release switch to weld at desired amperage level). C..When main amperage level is reached, initial switch can be released. D..Press and hold the final switch to decrease amperage at final slope rate (release switch to weld at desired amperage level). E.. When final amperage has been reached, the arc extinguishes and shielding gas flows for the time set on the Postflow control. Application: With the use of two remote switches instead of potentiometers, 3T gives the operator the ability to infinitely increase, decrease, or pause and hold amperage within the range determined by the initial, main, and final amperages. OM-2240 Page 51 6-4. Arc Timer/Counter Display 3/4 123 456 Or Or 1 2 1 And Rear Panel 1 2 Output And Amperage Controls Power Switch To display the arc timer/counter, turn power switch on, and then press the Amperage Control and Output switch pads before the software version clears the meters, and hold the switch pads until software version clears the meters OM-2240 Page 52 3 Arc Timer Display Upon power up as described above, the meter S LED will turn on, and arc time will be displayed for 5 seconds as [000 000 ] to [999 959 ]. The first four numbers indicate hours, and the last two numbers indicate minutes. Arc time shown in example is read as 1,234 hours and 56 minutes. Maximum arc time is 9,999 hours and 59 minutes. 4 Arc Counter After 5 seconds, the meter A LED turns on, and the arc counter will be displayed for the next 5 seconds as [000 000 ] to [999 999 ]. The maximum arc cycle count is 999 999. 6-5. Lockout Functions A. Accessing Lockout Capability 4 5 000 LL−0 -- 1 6 And 000 LL−0 L1 or 2,3,4 3 2 Rear Panel See Section 5-1 for explanation of controls referred to in all of Section 6-5. Toggle Amperage (A) switch pad to light the meter S LED. You may now select a lockout level. There are four (1−4) different lockout levels. Each successive level allows the operator more flexibility. There are four lockout levels available. Turn Encoder control to select a lockout level (see Sections B for lockout level descriptions). . Before activating lockout levels, be sure that all procedures and 6 parameters are established. Parameter adjustment is limited while lockout levels are active. 1 Amperage (A) Switch Pad 2 Adjust Switch Pad 3 Power Switch To access lockout screens, turn On power switch, and then before the software version clears the meters, push and hold the Amperage and Adjust switch pads until software version number clears meters. 4 Lockout Off Upon power up as described, the meter % and Amperage (A) switch pad LED’s light, and the meter display will be as shown for a lockout off condition. 5 Encoder Control To turn On the lockout feature, proceed as follows: Pressing Amperage (A) switch pad will toggle between the meter % and S LED’s. Toggle switch pad until % LED is on. Turn Encoder control to select a three digit lockout number. Number will appear on the voltage (left) meter. Select any number from [001] thru [999 ]. IMPORTANT: remember this three digit number, as you will need it to turn the lockout feature off. Lockout On Once the desired three digits have been entered and a lockout level selected, press torch trigger or turn Off power to complete lockout on sequence. . Setting a three digit lockout number of [000], or setting a lockout level of [L--] will cause a lockout off condition. To turn Off the lockout feature, proceed as follows: To access lockout screens, turn On power switch, and then before the software version clears the meters push and hold the Amperage and Adjust switch pads until software version number clears meters. Upon power up as described, the meter % and Amperage (A) switch pad LED’s will turn on, and the meter display will be as shown for a lockout on (see callout 6) condition. Use Encoder control to enter the same three digits that were used to turn on the lockout feature. Press the Amperage (A) switch pad. The meter % LED will turn off, and the S LED will light. The amperage (right) meter display will change to [L--]. The lockout feature is now off. Press torch trigger or turn Off power to complete lock out Off sequence. OM-2240 Page 53 B. LockOut Levels Level 1 . Before activating lock out lev- els, be sure that all procedures and parameters are established. Parameter adjustment is limited while lock out levels are active. Level 1 . Remote amperage control is not available in level 1. TIG Output Selection Use Output Switch Pad To Select A Trigger Method For The TIG Process If either the TIG HF Impulse or TIG Lift Arc process (see Section 5-8) was active when lockout level 1 was activated, the operator can choose between RMT STD (Remote Standard) or RMT 2T HOLD (Remote 2T Hold). The On function is also available if TIG Lift Arc was active. If RMT 2T HOLD was reconfigured (see Section 6-3C) prior to lockout level 1 activation, the reconfigured output mode (4T, 4T momentary, mini logic, or spot) is available to the operator instead of RMT 2T. Stick Output Selection If the Stick process was active when lockout level 1 was activated, the operator can choose between RMT STD or On. When parameter change or selection is limited by lock level 1, [L‐1 ] is displayed as a reminder. Level 2 . Remote amperage control is not available in level 2. Use Output Switch Pad To Select A Trigger Method For The Stick Process Level 2 Select Process Process Selection OM-2240 Page 54 Includes all the functions of level 1 plus Polarity and Process Selection (see Sections 5-6 and 5-8). When parameter change or selection is limited by lock level 2, [L‐2] is displayed as a reminder. B. Lock Out Levels (Continued) Level 3 Level 3 . Remote amperage control is not available in level 3. Use Encoder Control To Adjust Amperage +/− 10% Of Preset Value. Includes all the functions of levels 1 and 2 plus the following: +/− 10% adjustment of preset TIG or Stick Weld Amps Select desired process, TIG or Stick, and use Encoder control to adjust amperage +/− 10% of preset amperage value, up to the limits of the machine. If operator tries to go beyond the +/− 10%, the amperage (right) meter will display [L‐3 ] as a reminder. Pulser ON/Off Control Gives operator the ability to turn on/ off the Pulser control. Select Process +/− 10 % Amperage Adjust Control When parameter change or selection is limited by lock level 3, [L‐3] is displayed as a reminder. Level 4 Includes all the functions of levels 1, 2, and 3 plus the following: Remote Amperage Control Allows operator to use remote amperage control if desired. Remote control operates from minimum to maximum of preset amperage value. Connect remote control device according to Section 4-8. When parameter change or selection is limited by lock level 4, [L‐4] is displayed as a reminder. Turn Pulser Control On/Off Pulser On/Off Control Remote Amperage Control Level 4 A B K J I H C L N D M G E F OM-2240 Page 55 6-6. Setting Unit To Display PPP While Pulse Welding (DX Models Only) 5 PPP 4 sel --- 2 1 3 And Rear Panel 1 Output Switch Pad 2 Pulser Switch Pad 3 Power Switch To access the PPP while welding display, turn power switch on, and then press the Output and Pulser switch pads before the software version OM-2240 Page 56 clears the meters. Hold the switch pads until [SEL] [---] or [SEL] [PPP] appears. 4 Encoder Control 5 PPP Meter Display Turn Encoder to change between standard and (PPP) meter display. When the (PPP) meter display feature is active while pulse welding, the (PPP) will be displayed on the right meter display, and the Meter Hold feature is disabled. The (PPP) meter display feature will not effect the normal amperage display or Meter Hold capabilities when in a nonpulse welding mode. Press torch trigger or turn off power to save setting and end this set-up. 6-7. Stick Open-Circuit Voltage (OCV) Selection 5 6 sel loc 3 2 1 4 And Rear Panel 1 Process Switch Pad 2 Adjust Switch Pad 3 Amperage Switch Pad 4 Power Switch To access the Stick OCV selection, turn power switch on and then press the Process, Adjust and Amperage switch pads before the software ver- sion clears the meters. Hold the switch pads until [SEL] [Loc] or [SEL] [noc) appears. 5 Encoder Control 6 Meter Display Turn Encoder to change between low OCV [SEL] [Loc] and normal OCV [SEL] [noc]. Active selection is displayed on the meters. When Stick low OCV is selected, opencircuit voltage is between 9 and 14 volts. When Stick normal OCV is selected, open-circuit voltage is approximately 80 volts. Application: For most Stick applications use low open-circuit voltage. Use normal open-circuit voltage for hard to start Stick electrodes, or if required for your particular application. OM-2240 Page 57 6-8. Stick Stuck Check Selection 5 6 sel Sc 0 3 1 2 4 And Rear Panel 1 Process Switch Pad 2 Output Switch Pad 3 Amperage Switch Pad 4 Power Switch To access the Stick Stuck Check selection, turn power switch on and then press the Process, Output and Amperage switch pads before the software version clears the meters. Hold the switch pads until [SEL] [Sc0] or [SEL] OM-2240 Page 58 [sci) appears. 5 Encoder Control 6 Meter Display Turn Encoder to change between Stick Stuck Check off [SEL] [Sc0] and Stick Stuck Check on [SEL] [Sci]. Active selection is displayed on the meters. When Stick Stuck Check is on and the welding electrode (rod) is stuck, output is turned off. Application: For most Stick applications, use Stick Stuck Check off. With Stick Stuck Check on and the welding electrode (rod) stuck, output is turned off in an attempt to save the rod for reuse. This allows the operator time to un-stick the rod, or disconnect the rod holder from the rod without arc occurring. Turn Stick Stuck Check on when this function is desired. SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. A. Welding Power Source n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Δ = Repair l = Replace Δ = Repair l = Replace Every 3 Months nl Labels n l Gas Hoses Every 3 Months nΔ lCables And Cords Every 6 Months ! Do not remove case when blowing out inside of unit (see Section 7-2) . ~:Durning heavy service, clean monthly. B. Optional Cooler n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Every 3 Months ~Coolant Strainer, durning heavy service, clean more frequently. ~ Blow out heat exchanger fins. nCheck coolant level. Top off with distilled or deionized water if necessary. Every 6 Months nlHoses nl Labels Every 12 Months ZReplace coolant. OM-2240 Page 59 7-2. Blowing Out Inside Of Unit ! Do not remove case when blowing out inside of unit. To blow out unit, direct airflow through front and back louvers as shown. 803 428-A OM-2240 Page 60 7-3. Voltmeter/Ammeter Help Displays 0 V A HEL 1 P-0 V A HEL 2 3 4 HEL 5 HEL 0 Help 1 Display Indicates a malfunction in the primary power circuit caused by an overcurrent condition in the primary IGBT switching circuit. Contact a Factory Authorized Service Agent if this display is shown. 2 Help 2 Display Indicates an open in the thermal protection circuitry located on the bottom heat sink. Contact a Factory Authorized Service Agent if this display is shown. V 11 HEL P-5 Indicates a short in the thermal protection circuitry located on the bottom heat sink. Contact a Factory Authorized Service Agent if this display is shown. 1 HEL A Help 0 Display A V 10 P-4 3 V HEL A front of the unit. All circuitry referred to is located inside the unit. P-8 V 9 P-3 . All directions are in reference to the HEL HEL A V A V 8 P-2 V V HEL A V HEL 7 P-1 V HEL 6 Help 3 Display 7 P-9 A P10 A P12 A P16 A P21 Help 9 Display Indicates the bottom heat sink has overheated. The unit has shut down to allow the fan to cool it (see Section 4-5). Operation will continue when the unit has cooled. Indicates a short in the thermal protection circuitry located on the top heat sink. Contact a Factory Authorized Service Agent if this display is shown. 4 8 Help 4 Display Indicates an open in the thermal protection circuitry located on the top heat sink. Contact a Factory Authorized Service Agent if this display is shown. 5 Help 5 Display Indicates the top heat sink has overheated. The unit has shut down to allow the fan to cool it (see Section 4-5). Operation will continue when the unit has cooled. 6 Help 8 Display Indicates a malfunction in the secondary power circuit of the unit. There is a high open circuit condition. Contact a Factory Authorized Service Agent if this display is shown. Help 10 Display Indicates torch trigger is depressed. Release trigger to continue. 9 Help 12 Display Indicates an improper set-up. You are trying to make an adjustment that is not allowed. 10 Help 16 Display Secondary clamp voltage too high. Straighten out or shorten weld cables. If this does not correct the problem, contact a Factory Authorized Service Agent. 11 Help 21 Display Indicates voltage or current feedback has been detected with contactor off. Contact a Factory Authorized Service Agent if this display is shown. OM-2240 Page 61 7-4. Troubleshooting Trouble No weld output; unit completely inoperative. Remedy Place line disconnect switch in On position (see Section 4-14 or 4-15). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-14 or 4-15). Check for proper input power connections (see Section 4-14 or 4-15). No weld output; meter display On. If using remote control, be sure correct process is enabled to provide output control at Remote 14 receptacle (see Section 4-8 as applicable). Input voltage outside acceptable range of variation (see Section 4-13). Check, repair, or replace remote control. Unit overheated. Allow unit to cool with fan On (see Section 4-5). Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-7). Clean and tighten all weld connections (see Section 4-7). Fan not operating. Check for and remove anything blocking fan movement. Have Factory Authorized Service Agent check fan motor. Wandering arc Use proper size tungsten (see Section 11). Use properly prepared tungsten (see Section 11). Reduce gas flow rate (see Section 4-9). Tungsten electrode oxidizing and not re- Shield weld zone from drafts. maining bright after conclusion of weld. Increase postflow time (see Section 5-1). Check and tighten all gas fittings (see Section 4-9). Water in torch. Refer to torch manual. OM-2240 Page 62 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-2240 Page 63 SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram OM-2240 Page 64 237 567-A SECTION 9 − HIGH FREQUENCY (HF) 9-1. Welding Processes Requiring High Frequency 1 High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. 1 Work TIG 9-2. Correct Installation 6 Weld Zone 50 ft (15 m) 50 ft (15 m) 4 1 5 2 7 3 7 Ground All Metal Objects And All Wiring In Welding Zone Using #12 AWG Wire Nonmetal Building 8 Ground Workpiece If Required By Codes 7 7 10 Metal Building 9 1 HF Source (Welder With Built-In HF Or Separate HF Unit) Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable. Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m). 5 Water Pipes And Fixtures 8 Metal Building Panel Bonding Methods Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame. Ground water pipes every 50 ft (15 m). 9 A circle 50 ft (15 m) from centerpoint between HF source and welding torch in all directions. 6 Cover all windows and doorways with grounded copper screen of not more than 1/4 in (6.4 mm) mesh. 3 7 2 Welding Zone And Centerpoint Weld Output Cables Keep cables short and close together. 4 Conduit Joint Bonding And Grounding External Power Or Telephone Lines Locate HF source at least 50 ft (15 m) away from power and phone lines. Grounding Rod Consult the National Electrical Code for specifications. Windows And Doorways 10 Overhead Door Track Ground the track. OM-2240 Page 65 SECTION 10 − SETUP GUIDES FOR (GTAW) TIG WELDING 10-1. Typical GTAW Set-Ups A. AC − GTAW 1/8 in. Aluminum Set-Up Ammeter This symbol indicates which functions should be active for aluminum. Encoder 207 694-A • Turn power on (switch located on rear panel) • Press Polarity switch pad until AC LED is lit • Press Process switch pad until TIG HF Impulse LED is lit • Press Output switch pad until RMT STD LED is lit • Press Adjust switch pad until Post Flow LED is lit • Turn Encoder control to set 15 seconds of Post Flow time • Press AC Waveshape switch pad until Balance LED is lit • Turn Encoder control to set desired Balance (65 - 80%) • Press AC Waveshape switch pad until AC Frequency LED is lit • Turn Encoder control to set desired AC Frequency (100 - 150 Hz) • Press Amperage A switch pad until LED is lit • Turn Encoder control to set desired amperage (125 - 160 amps). . The ammeter displays the parameter for any of the following units of measure when they are active: amperage, time, percentage, or frequency. The corresponding LED, located directly below the ammeter, will also light up. The ammeter also displays actual amperage while welding. Om-2240 Page 66 B. DC - GTAW 16 Gauge Stainless Steel Set-Up Ammeter Encoder 207 694-A This symbol indicates which functions should be active for stainless steel. • Turn power on (switch located on rear panel) • Press Polarity switch pad until DC LED is lit • Press Process switch pad until TIG HF Impulse LED is lit • Press Output switch pad until RMT STD LED is lit • Press Adjust switch pad until Post Flow LED is lit • Turn Encoder control to set 8 seconds of Post Flow time • Press Amperage A switch pad until LED is lit • Turn Encoder control to set desired amperage (50 - 80 amps). . The ammeter displays the parameter for any of the following units of measure when they are active: amperage, time, percentage, or frequency. The corresponding LED, located directly below the ammeter, will also light up. The ammeter also displays actual amperage while welding. OM-2240 Page 67 SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2007_05 ! Whenever possible and practicle, use DC weld output instead of AC weld output. 11-1. 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 .010” (1 mm) Up to 25 Up tp 20 .020” (1 mm) 15-40 15-35 .040” (1 mm) 25-85 20-80 1/16” (1.6 mm) 50-160 50-150 3/32” (2.4 mm) 135-235 130-250 1/8” (3.2 mm) 250-400 225-360 5/32” (4.0 mm) 400-500 300-450 3/16” (4.8 mm) 500-750 400-500 1/4” (6.4 mm) 750-1000 600-800 ♦Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour). Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers. 11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines ! Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away. Radial Grinding Causes Wandering Arc 2-1/2 Times Electrode Diameter 1 3 2 1 Grinding Wheel Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality. 2 Tungsten Electrode A 2% ceriated tungsten is recommended. 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. OM-2240 Page 68 SECTION 12 − GUIDELINES FOR (GTAW) TIG WELDING gtaw 7/2006 12-1. 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 tungsten according to Section 11. 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-2240 Page 69 12-2. Torch Movement During Welding Tungsten Without Filler Rod 75° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod 75° Welding direction Form pool 15° Tilt torch Remove rod Add filler metal Move torch to front of pool. Repeat process. ST-162 002-B 12-3. Positioning Torch Tungsten For Various Weld Joints “T” Joint Butt Weld And Stringer Bead 20° 90° 70° 75° 20° 10° 15° Corner Joint Lap Joint 20-40° 90° 75° 75° 15° 15° 30° ST-162 003 / S-0792 OM-2240 Page 70 SECTION 13 − SETUP GUIDE FOR (SMAW) STICK WELDING 13-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) 1 1 Front Panel Correct front panel display for basic Stick DCEP welding. . For all front panel switch pad controls: press switch pad to turn on light and enable function. . Gray on nameplate indicates a Stick function (see Section 5-1 for description of controls). 207 694-A OM-2240 Page 71 SECTION 14 − GUIDELINES FOR (SMAW) STICK WELDING 7014 7018 7024 Ni-Cl 308L OM-2240 Page 72 ALL DEEP EP ALL DEEP 6013 EP,EN ALL LOW GENERAL 7014 EP,EN ALL MED 7018 EP ALL LOW SMOOTH, EASY, FAST LOW HYDROGEN, STRONG 7024 EP,EN NI-CL EP FLAT HORIZ FILLET ALL 308L EP ALL USAGE PENETRATION EP 6011 AC 6010 DC* 450 400 350 300 AMPERAGE RANGE 250 200 150 POSITION 6013 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 ELECTRODE 6010 & 6011 100 50 DIAMETER ELECTRODE 14-1. Electrode and Amperage Selection Chart MIN. PREP, ROUGH HIGH SPATTER LOW SMOOTH, EASY, FASTER LOW CAST IRON LOW STAINLESS *EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY) Ref. S-087 985-A 14-2. Stick Welding Procedure NOTICE − Weld current starts when electrode touches workpiece. 5 NOTICE − Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. 4 2 1 Workpiece Make sure workpiece is clean before welding. 2 3 3 A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 14-1). 6 1 Work Clamp Electrode 7 4 5 6 Insulated Electrode Holder Electrode Holder Position Arc Length Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. Tools Needed: 7 Slag Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass. stick 12/96 − ST-151 593 14-3. Striking an Arc − Scratch Start Technique 1 1 2 3 Electrode Workpiece Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. 2 3 NOTICE − Normal open-circuit voltage (80 volts) is present if normal open-circuit voltage is selected (see Section NO TAG ). S-0049 14-4. Striking an Arc − Tapping Technique 1 1 2 3 2 Electrode Workpiece Arc Bring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. 3 S-0050 OM-2240 Page 73 14-5. Positioning Electrode Holder 10°-30° 90° 90° End View of Work Angle Side View of Electrode Angle GROOVE WELDS 10°-30° 45° 45° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 14-6. Poor Weld Bead Characteristics 1 2 3 4 5 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 1 2 4 3 5 S-0053-A 14-7. Good Weld Bead Characteristics 1 2 3 Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded. 4 5 1 2 3 4 No Overlap Good Penetration into Base Metal 5 S-0052-B OM-2240 Page 74 14-8. Conditions That Affect Weld Bead Shape . Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Angle Too Small Correct Angle 10° - 30° Angle Too Large Drag ELECTRODE ANGLE Spatter Normal Too Short Too Long ARC LENGTH Normal Slow Fast TRAVEL SPEED S-0061 14-9. Electrode Movement During Welding . Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better. 1 2 1 2 3 Stringer Bead − Steady Movement Along Seam Weave Bead − Side to Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode. 3 S-0054-A OM-2240 Page 75 14-10. Butt Joints 1 1 2 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 1/16 in (1.6 mm) Single V-Groove Weld Good for materials 3/16 − 3/8 in (5-9 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels. 30° 4 3 Create 30 degree angle of bevel on materials in V-groove welding. 4 Double V-Groove Weld Good for materials thicker than 3/8 in (9 mm). S-0662 14-11. Lap Joint 30° Or Less 30° Or Less 1 1 Single-Layer Fillet Weld Electrode Single-Layer Fillet Weld Move electrode in circular motion. 3 Multi-Layer Fillet Weld Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength. 3 2 1 2 Multi-Layer Fillet Weld S-0063 / S-0064 14-12. Tee Joint 1 2 Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. 1 2 45° Or Less Electrode Fillet Weld For maximum strength weld both sides of upright section. 2 3 Multi-Layer Deposits Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section 14-9. Remove slag before making another weld pass. 1 3 OM-2240 Page 76 S-0060 / S-0058-A / S-0061 14-13. Weld Test 1 2 3 3 Strike weld joint in direction shown. A good weld bends over but does not break. 3 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) Vise Weld Joint Hammer 2 To 3 in (51-76 mm) 2 2 1 1 S-0057-B 14-14. Troubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding. 14-15. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high. Reduce arc length or voltage. OM-2240 Page 77 14-16. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding. Adjust work angle or widen groove to access bottom during welding. Momentarily hold arc on groove side walls when using weaving technique. Keep arc on leading edge of weld puddle. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding. 14-17. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Reduce travel speed. 14-18. Troubleshooting − Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Possible Causes Excessive heat input. Good Penetration Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. OM-2240 Page 78 14-19. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Excessive heat input. Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 14-20. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. Possible Causes Unsteady hand. Corrective Actions Use two hands. Practice technique. 14-21. Troubleshooting − Distortion Distortion − contraction of weld metal during welding that forces base metal to move. Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input. Corrective Actions Use restraint (clamp) to hold base metal in position. Make tack welds along joint before starting welding operation. Select lower amperage for electrode. Increase travel speed. Weld in small segments and allow cooling between welds. OM-2240 Page 79 SECTION 15 − PARTS LIST . Hardware is common and not available unless listed. 11 12 13 28 28 615 25 41 18 16 19 2 10 402 8 6 7 401 400 32 14 44 3 43 15 4 17 1 29 614 42 600 5 Figure 15-1. Main Assembly OM-2240 Page 80 803 395-G Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-1. Main Assembly . . . 1 . . . . . . . . . . Fig 15-2 . . . 2 . . . . . . . . . . Fig 15-3 . . . 3 . . . . . . . . . . Fig 15-4 . . . 4 . . . . . . . . . . Fig 15-5 . . . 5 . . . . . . . . . . Fig 15-7 . . . 6 . . . . S1 . . . 231191 . . . 7 . . . . . . . . . . 210267 . . . 8 . . . PM1 . . 204821 . . . 10 . . . . . . . . . +196727 . . . 11 . . . . . . . . . +209709 . . . 12 . . . . . . . . . . 206108 . . . 13 . . . . . . . . . . 195663 . . . 14 . . . . . . . . . . 189782 . . . 15 . . C7, C8 213974 . . . 16 . . . . . . . . . . 209980 . . . 17 . . . . . . . . . . 235494 . . . 18 . . . . . . . . . . 189768 . . . 19 . . . . . . . . . . 189779 . . . 25 . . . . . . . . . . 210166 . . . 28 . . . . . . . . . . 203990 . . . 29 . . . . . . . . . . 185835 . . . 32 . . . . . . . . . . 182826 . . . 39 . . . . . . . . . . Deleted . . . 40 . . . . . . . . . . Deleted . . . 41 . . . . . . . . . . 215002 . . . 42 . . . HD1 . . 198028 . . 400 . . PC2 . . 207818 . . 401 . . PC1 . . 237558 . . 402 . PC10 . 235406 . . 403 . . . . . . . . . Deleted . . 600 . . . . . . . . . 229333 . . 614 . . . . . . . . . 136343 . . 615 . . . . . . . . . 229334 . . . . . . . . . . . . . . . . 245650 . . . . . PANEL, FRONT W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, REAR W/CMPNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAGNETICS SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDTUNNEL, W/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH,TGL 3PST 50A 600VAC SCR TERM WIDE TGL . . . . . . . . . . . . . . . . . PLUG, W/LEADS SECONDARY GATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KIT, MODULE, INPUT/PRE−REGULATOR/INVERTER . . . . . . . . . . . . . . . . . . . . CABLE, POWER 10 FT 12GA 4C BLK/RED/WHT/GRNYEL . . . . . . . . . . . . . . . WRAPPER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STRAP, SHOULDER 6 FT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, INTERCONNECT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLUG, W/LEADS VFB, LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLUG, W/LEADS ARC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLUG, W/LEADS GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, LEM W/PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, WARNING GENERAL PRECAUTIONARY . . . . . . . . . . . . . . . . . . . . . . . LABEL, WARNING ELECTRIC SHOCK/EXPLODING PARTS . . . . . . . . . . . . . . LABEL, WARNING ELECTRIC SHOCK POWER CORD . . . . . . . . . . . . . . ...... ...... . . . . . CLIP, SUPPORT PC MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSDUCER, CURRENT 100A MODULE SUPPLY V +/− 15V . . . . . . . . . . . CIRCUIT CARD ASSY, POWER INTERCONNECT . . . . . . . . . . . . . . . . . . . . . . . KIT, FIELD CIRCUIT CARD INVERTER MAX / DYN 200 & PM . . . . . . . . . . . . CIRCUIT CARD ASSY, BOOST CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . SCREW, M10−1.5 X 20 HEX HD−PLN 8.8 PLD SEMS . . . . . . . . . . . . . . . . . . . . SCREW, K50X 20 PAN HD−PHL STL PLD PT THREAD FORMING . . . . . . . . . SCREW, M 5− .8 X 35 PAN HD−PHL STL PLD SEMS . . . . . . . . . . . . . . . . . . . . . LABEL, WARNING EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 1 1 1 1 2 2 2 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-2240 Page 81 400 . Hardware is common and not available unless listed. 604 1 7 3 4 603 5 6 14 13 12 2 602 9 11 8 Item No. Dia. Mkgs. ... 1 .......... ... 2 .......... ... 3 .......... ... 3 .......... ... 4 .......... ... 5 .......... ... 6 .......... ... 6 .......... . . . 7 . . . RC1 . . ... 8 .......... ... 9 .......... . . . 11 . . . . . . . . . . . . . 12 . . . . . . . . . . . . . 13 . . . . . . . . . . . . . 14 . . . . . . . . . . . . . 15 . . . . . . . . . . . . . 16 . . . . . . . . . . . . 400 . . PC3 . . . . 602 . . . . . . . . . . . 603 . . . . . . . . . . . 604 . . . . . . . . . 16 194242 210171 239471 231255 174992 194243 199008 199009 189771 202553 193649 185712 185713 229338 185717 185718 186228 235479 166560 178548 212367 803 391-B Figure 15-2. Panel, Front w/Components Part No. 207 698 15 Description Quantity Figure 15-2. Panel Front w/Components (Figure 15-1 Item 1) ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... PANEL, FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, FRONT LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEMBRANE, SWITCH CONTROL DYNASTY 200 SD . . . . . . . . . . . . . . . MEMBRANE, SWITCH CONTROL DYNASTY 200 DX . . . . . . . . . . . . . . . KNOB, POINTER .840 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . . DOOR, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, DOOR 200 SD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, DOOR 200 DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE W/LEADS&PLUG, (14 PIN) . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, TWIST LOCK (FEMALE) POWER . . . . . . . . . . . . . . . . . . . FTG, GAS BARBED 1/4 TBG 5/8−18 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, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, CONTROL & INTERFACE W/PROGRAM . . . . . RING, RTNG EXT .500 SHAFT X .042 THK E STYLE BOWED . . . . . . . TERMINAL, CONNECTOR FRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND−OFF, NO 6−32 X .625 LG .250 HEX STL M&F . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 2 1 1 1 4 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-2240 Page 82 . Hardware is common and not available unless listed. 3 5 601 4 1 600 6 605 2 803 392-A Figure 15-3.Panel, Rear w/Components Item No. Dia. Mkgs. Part No. 210 158 1 .................. 2 .................. 3 .................. 4 .................. 5 .................. 6 .................. 600 . . . . . . . . . . . . . . . . 601 . . . . . . . . . . . . . . . . 605 . . . . . . . . . . . . . . . . 194242 206053 210159 201155 193649 211165 198245 166560 136343 Description Quantity Figure 15-3. Panel, Rear w/Components (Figure 15-1 Item 2) .... .... .... .... .... .... .... .... .... PANEL, FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, REAR LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, REAR UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, STRAIN RELIEF .450/ .709 ID X1.608 MTG HOL . . . . . . . . . FTG, GAS BARBED 1/4 TBG 5/8−18 FEMALE . . . . . . . . . . . . . . . . . . . . BRACKET, HEATSINK SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, CONDUIT .750 NPT PLD 1.388 OD X .150 THK . . . . . . . . . . . . . . RING, RTNG EXT .500 SHAFT X .042 THK E STYLE BOWED . . . . . . SCREW, K50 X 20 PAN HD-PHL STL PLD THREAD FORMING . . . . . . 1 1 1 1 1 1 1 1 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-2240 Page 83 . Hardware is common and not available unless listed. 3 613 1 609 7 17 21 19 4 617 17 614 8 611 15 600 2 12 400 9 11 23 14 6 13 22 Item No. Dia. Mkgs. Figure 15-4. Magnetics Assembly w/Components Part Description No. 803 427-B Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 6 7 8 9 11 12 13 14 15 17 19 . . . . . . . . . . 195649 . . . . . . . . . . 189785 . . . FM1 . . 239380 . . . GS1 . . 238805 . . . CR1 . . 198549 . . . . . . . . . . . 112863 . . . . Z1 . . 189790 . . . . L2 . . 210599 . . . . T1 . . 209693 . . . . . . . . . . 109056 . . . . . . . . . . 196512 . . . . . . . . . . 196514 . . . . . . . . . . 200385 . . . . . . . . . . 210610 . . . . . . . . . . 231208 OM-2240 Page 84 ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... PANEL, PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, HF COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN, MUFFIN 24VDC 3200 RPM 141 CFM 4.125 MTG HOLES . . . . . . VALVE, 24VDC 2WAY 125 P.S.I. CUSTOM PORT .054 ORF W/FRICT RELAY, ENCL 24VDC SPST 35A/300VAC 4PIN FLANGE MTG . . . . . . . FTG, HOSE BRS BARBED M 1/4 TBG X 5/8−18 SAE FLARE . . . . . . . . ASSY, OUTPUT INDUCTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COIL, INDUCTOR 9T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XFMR, HF LITZ/LITZ W/BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CORE, FERRITE E 2.164 LG X 1.094 HIGH X .826 WIDE . . . . . . . . . . . . BRACKET, INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKET, INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, MTG HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOSE, NPRN BRD NO 1 X .250 ID X 12.250 . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, FASTON 1/4 RING W/75 DEG BEND . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 Item No. Dia. Mkgs. Part No. Description Quantity Figure 15-4. Magnetics Assembly w/Components (Figure 15-1 Item 3) (Continued) . . . 22 . . . . T2 . . 233191 . . . 23 . . . . . . . . . . 237554 . . 400 . . PC7 . . 235471 . . 600 . . . . . . . . . 199538 . . 603 . . . . . . . . . 057357 . . 609 . . . . . . . . . 137761 . . 611 . . . . . . . . . . 231179 . . 613 . . . . . . . . . 212167 . . 614 . . . . . . . . . 010381 . . 617 . . . . . . . . . 170647 ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... COIL XFMR, COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, XFMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, ARC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . GROMMET, SCR NO 8/10 PANEL HOLE .281 SQ .250 HIGH . . . . . . . . . BUSHING, SNAP−IN NYL .937 ID X 1.125 MTG HOLE . . . . . . . . . . . . . . NUT, 750NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, K50X 20 PAN HD−PHL STL PLD PT THREAD FORMING . . . . STANDOFF, NO 8−32 X .625 LG .250 NYL HEX FEM THREADED . . . . CONNECTOR, RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, SNAP−IN NYL 1.312 ID X 1.500 MTG HOLE . . . . . . . . . . . . . 1 1 1 2 2 1 2 2 1 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-2240 Page 85 . Hardware is common and not available unless listed. 7 13 14 11 10 1 12 4 602 2 8 6 Figure 15-5. Windtunnel w/Components Item No. Dia. Mkgs. Part No. 210 162 . . . 1 . . . . . . . . . . 195645 . . . 2 . . . . . . . . . . 210264 . . . 4 . . . . . . . . . . 232857 . . . 6 . . . . . . . . . +209949 . . . 7 . . . . . . . . . . 232851 . . . 8 . . . . L1 . . 189787 . . . 10 . . . . . . . . . . . 211169 . . . 11 . . . . L3 . . 210568 . . . 12 . . . . . . . . . . 109056 . . . 13 . . . . . . . . . . 196512 . . . 14 . . . . . . . . . . 196514 . . 602 . . . . . . . . . 154408 ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... Description 803 425-A Quantity Figure 15-5. Windtunnel w/Components (Figure 15-1 Item 4) BRACKET, HEATSINK REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, FRONT HEATSINK MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAIL, HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEAT SINK, PRIMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEAT SINK, SECONDARY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDUCTOR, INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAIL, HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COIL, INDUCTOR 14T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CORE, FERRITE E 2.164 LG X 1.094 HIGH X .826 WIDE . . . . . . . . . . . . BRACKET, INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKET, INDUCTOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, SNAP-IN NYL .562 ID X .875 MTG HOLE CENT . . . . . . . . . 1 1 2 1 1 1 2 1 1 1 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-2240 Page 86 . Hardware is common and not available unless listed. 12 11 6 9 10 8 7 5 2 4 1 803 426-D Figure 15-6. Heat Sink, Secondary Assembly Item No. Dia. Mkgs. Part No. 232 851 ... ... ... ... ... ... ... ... ... ... ... 1 2 4 5 6 7 8 9 10 11 12 . . . . . . . . . . 209984 . . D1,D2 . 212037 . . . RT1 . . . 211124 PM2,PM3 213179 . . . . . . . . . . 210278 . . . . . . . . . . 199952 . . . . . . . . . . 239381 . . . . . . . . . . 210279 . . PC11 . 208060 . . . PC6 . ♦207826 . . . . . . . . . . 218 597 ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... Description Quantity Figure 15-6. Heat Sink, Secondary Assembly(Figure 15-5 Item 7) HEAT SINK, SECONDARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KIT, DIODE ULTRA−FAST RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMISTOR, NTC 30K OHM @ 25 DEG C 18IN LEAD #8 . . . . . . . . . . TRANSISTOR, IGBT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, POSITIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIODE, POWER MODULE 50 AMP 600 V 1PH FAST RECOVE . . . . . . . BUS BAR, NEGITIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUS BAR, OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, DIODE SNUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, IGBT SNUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . CLIP, SUPPORT IGBT GATE DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 2 1 1 2 1 1 2 ♦For models prior to Serial No. LE200084, order kit 220 384 (kit contains PC board 207826 and clips 220384). 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-2240 Page 87 . Hardware is common and not available unless listed. Figure 15-7. Base Assembly Item No. Dia. Mkgs. Part No. 207 689 Description 803 394−A Quantity Figure 15-7. Base Assembly (Figure 15-1 Item 5) 1 . . . . . . . . . . . . . . . . . . 207255 . . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . . . . . . . . . . . 239388 . . . . BUMPER, RBR .875 OD x .188 ID x .39 HIGH RECESSED . . . . . . . . . 4 3 . . . . . . . . . . . . . . . . . . 211478 . . . . INSULATOR, BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-2240 Page 88 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-2240 Page 89 SECTION 16 − COOLER PARTS LIST . Hardware is common and not available unless listed. 11 10 13 3 12 2 7 16 7 18 15 14 19 1 8 13 6 6 9 17 5 22 7 4 21 15 20 25 23 19 24 26 27 28 805 266-A Figure 16-1. Cooler Main Assembly OM-2240 Page 90 Item No. Dia. Mkgs. Part No. Description Quantity Figure 16-1. Cooler Main Assembly 1 . . . . . . . . . . . . . +235416 . . Wrapper, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 188980 . . Label, Caution Incorrect Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . . . . . . . . . . . . . . 203990 . . Label, Warning General Precautionary Static . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . . . . . . . . . . . . . . 235422 . . Tank, Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . . . . . . . . . . . . . . 166608 . . Cap, Tank Screw−on W/Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . . . . . . . . . . . . . . 237537 . . Hose, Rbr Brd No 1 X .375 ID X 11.250 Black . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . . . . . . . . . . . . . . 237535 . . Hose, Rbr Brd No 1 X .375 ID X 2.250 Black . . . . . . . . . . . . . . . . . . . . . . . . . 3 8 . . . . . . . . . . . . . . 166564 . . Filter, In−line Low Profile 100 Screen 3/8 Hose Bar . . . . . . . . . . . . . . . . . . . 1 9 . . . . . . . . . . . . . . 235419 . . Bracket, Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10 . . . . . . FM . . 213072 . . Fan, Muffin 115V 60 Hz 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . . 1 10 . . . . . . FM . . 235504 . . Fan, Muffin 230V 60 Hz 3400 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . . . . . 1 11 . . . . . . . . . . . . . 235418 . . Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12 . . . . . . . . . . . . . 237543 . . Radiator, Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 13 . . . . . . . . . . . . . 237538 . . Hose, Rbr Brd No 1 X .375 ID X 18.000 Black . . . . . . . . . . . . . . . . . . . . . . . . 1 14 . . . . . . . . . . . . . 237539 . . Hose, Rbr Brd No 1 X .375 ID X 11.50 Black . . . . . . . . . . . . . . . . . . . . . . . . . 1 15 . . . . . . . . . . . . . 237536 . . Hose, Rbr Brd No 1 X .375 ID X 9.00 Black . . . . . . . . . . . . . . . . . . . . . . . . . . 2 16 . . . . . . . . . . . . . 235461 . . Damper, Fluid Pulsation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 17 . . . . . . MOT . 235457 . . Pump, Assy Coolant (115V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 17 . . . . . . MOT . 235501 . . Pump, Assy Coolant (230V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 18 . . . . . PLG1 . 192457 . . Cable, Power 11 Ft 7 In 16ga 3c (115V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 18 . . . . . PLG1 . 192458 . . Cable, Power 11 Ft 7 In 16ga 3c (230V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 19 . . . . . . . . . . . . . 235423 . . Bezel, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 20 . . . . . . . . . . . . . 240279 . . Valve, Check 3/8 Barb Inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 21 . . . . . . . . . . . . . 094263 . . Clamp, 1−ear Type Nom Dim .718 X .276 Wide . . . . . . . . . . . . . . . . . . . . . . 14 22 . . . . . . . . . . . . . 235417 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 23 . . . . . . . . . . . . . 235415 . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 24 . . . . . . . . . . . . . 019663 . . Mount, NPRN 15/16 OD x 3/8 Rec 3/16 x 3/8 . . . . . . . . . . . . . . . . . . . . . . . . 4 25 . . . . . . . S1 . . 237540 . . Switch, Rocker Dpst 16 A 115 VAC On−Off . . . . . . . . . . . . . . . . . . . . . . . . . . 1 25 . . . . . . . S1 . . 237541 . . Switch, Rocker Dpst 16 A 230 VAC On−Off . . . . . . . . . . . . . . . . . . . . . . . . . . 1 26 . . . . . . . . . . . . . 235499 . . Ftg, Coolant Barbed 3/8 Tbg 5/8−18 Female . . . . . . . . . . . . . . . . . . . . . . . . . 2 27 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Miller Coolmate 1 (Order By Model And Serial Number) . . . . . 1 28 . . . . . . . . . . . . . 287120 . . Label, Notice Pump Priming Noise Can Occur During . . . . . . . . . . . . . . . . . 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. +When ordering a component originally displaying a precautionary label, the label should also be ordered. OM-2240 Page 91 SECTION 17 − CART PARTS LIST . Hardware is common and not available unless listed. 17 7 1 . Item 4 can be mounted in 7 alternative position if desired. 3 4 17 5 16 6 12 2 8 9 10 9 15 14 6 11 12 13 805 337-B Figure 17-1. Cart Main Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 17-1. Cart Main Assembly 1 . . . . . . . . . . . . . . . . . . 235507 2 . . . . . . . . . . . . . . . . . . 227147 3 . . . . . . . . . . . . . . . . . +237593 4 . . . . . . . . . . . . . . . . . . 237594 5 . . . . . . . . . . . . . . . . . . 235521 6 . . . . . . . . . . . . . . . . . . 235527 7 . . . . . . . . . . . . . . . . . . 195666 8 . . . . . . . . . . . . . . . . . . 235515 9 . . . . . . . . . . . . . . . . . . 602250 10 . . . . . . . . . . . . . . . . . 163463 11 . . . . . . . . . . . . . . . . . 121614 12 . . . . . . . . . . . . . . . . . 231184 13 . . . . . . . . . . . . . . . . . 235517 14 . . . . . . . . . . . . . . . . . 168663 15 . . . . . . . . . . . . . . . . . 210224 16 . . . . . . . . . . . . . . . . +235518 17 . . . . . . . . . . . . . . . . . 200285 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. Handle, Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screw, 250−20x .62 Pan Hd−torx Stl Pld Blk Tap−r . . . . . . . . . . . . Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Strap, Tie Down 1.000 w X 60.000 lg (300lbs) . . . . . . . . . . . . . . . . Bolt, Crg Stl .312−18 X 1.500 Gr2 Pld Zinc Clear . . . . . . . . . . . . . Screw, 010−32 x .50 Pan Hd−torx W/Gndrng Stl Pld . . . . . . . . . . Tray, Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washer, Flat .812 ID x 1.469 OD x .134t Stl Pld Ansi.750 . . . . . . Wheel, Rbr Tire 10.000 OD X 2.000 Wide X .750 Bore . . . . . . . . Ring, Rtng Ext .750 Shaft X .085 Thk E Style Pld . . . . . . . . . . . . . Nut, 312−18 .50 Hex .27h Stl Pld Sem Cone Wshr.76d . . . . . . . . Bottle Tray Assy, Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hook, spring .250, 2.375 Lg, .312 Snap Opening . . . . . . . . . . . . . Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support, Bottle/Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Warning Cylinder May Explode If Damaged . . . . . . . . . . . . 1 4 1 2 2 8 7 1 4 2 2 8 1 4 2 1 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. +When ordering a component originally displaying a precautionary label, the label should also be ordered. OM-2240 Page 92 Effective January 1, 2009 (Equipment with a serial number preface of LK or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls its original retail purchaser that new Miller equipment sold after * APT & SAF Model Plasma Cutting Torches the effective date of this limited warranty is free of defects in * Remote Controls material and workmanship at the time it is shipped by Miller. THIS * Accessory (Kits) WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor) WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns Within the warranty periods listed below, Miller will repair or * Canvas Covers replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor. 1. 2. 3. 4. 5. 5 Years Parts — 3 Years Labor * Original main power rectifiers only to include SCRs, diodes, and discrete rectifier modules 3 Years — Parts and Labor * Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Inverter Power Sources (Unless Otherwise Stated) * Water Coolant Systems (Integrated) * Intellitig * Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor Unless Specified * Motor Driven Guns (w/exception of Spoolmate Spoolguns) * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources, Coolers, and Electronic Controls/Recorders * Water Coolant Systems (Non-Integrated) * Flowgauge and Flowmeter Regulators (No Labor) * HF Units * Grids * Spot Welders * Load Banks * Fume Extractors * Arc Stud Power Sources & Arc Stud Guns * Racks * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF Models) * Field Options (NOTE: Field options are covered under True Blue® for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) * Bernard-Branded Mig Guns (No Labor) * Weldcraft-Branded TIG Torches (No Labor) * Subarc Wire Drive Assemblies 6 Months — Batteries 90 Days — Parts * MIG Guns and Subarc (SAW) Guns Miller’s True Blue® Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.) 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. 3. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 2009−01 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams For International Locations Visit www.MillerWelds.com Welding Process Handbooks To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 © 2009 Miller Electric Mfg. Co. 2009−01
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