Miller | LA169073 | Owner Manual | Miller DYNASTY 300 DX User manual

Miller DYNASTY 300 DX User manual
OM-358
188 291H
June 2000
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
230/460 Volt Models W/Autolink
400 Volt Models
Arc Welding Power Source

Dynasty 300 DX
And Non-CE Models
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding figure out what the problem is. The parts list
equipment manufacturer in will then help you to decide which exact part
the U.S.A. to be registered to
the ISO 9001 Quality System you may need to fix the problem. Warranty and
Standard.
service information for your particular model
are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
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.)
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturer’s Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. 115 Volts AC Duplex Receptacle, Circuit Breaker CB1 (Optional), And Power Switch . . . . .
3-6. Weld Output Terminals and Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Remote Program Select Inputs (Optional For Non CE Models) . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10.Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11.Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Description Of Controls (Use With Sections A And B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Remote Trigger (Normal) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Remote Trigger (2T) Hold Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. 4T (Specific Trigger Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Reconfiguring 4T For Mini Logic Control, Spot, Or Contactor On Lift-Arc . . . . . . . . . . . . . . . .
4-7. Mini Logic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Spot Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Contactor On Lift-Arc Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10.Lift-Arct And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11.Programmable HF Start Amperage And Time Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12.Arc Timer/Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13.Lock Out Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Blowing Out Inside of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – SELECTING AND PREPARING
TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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Declaration of Conformity For
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit.)
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
Dynastyt 300 DX
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Capability Directives: 89/336, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(December 1996 – Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
European Contact:
Telephone:
Fax:
dec_con1 10/95
Mr. Luigi Vacchini, Managing Director
MILLER Europe S.P.A.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-358 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-358 Page 2
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-358 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-358 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Y Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de
sécurité.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
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 quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal-métal
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.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimentation électrique.
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.
D Ne jamais toucher les pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.
D
D
D
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
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 et mettre à la terre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
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 Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
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.
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
D
D
D
D
D
D Eloigner votre tête des fumées. Ne pas respirer
les fumées.
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
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.
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.
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 si nécessaire, 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.
OM-358 Page 5
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 intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées
pendant le soudage.
D Porter un casque de soudage muni d’un écran de filtre approprié 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 protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
D Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds.
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 Se protéger et d’autres personnes de la projection d’étincelles et de
métal chaud.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur
des substances inflammables.
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 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 Brancher le câble 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 et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
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.
DES PARTICULES VOLANTES
peuvent blesser 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.
OM-358 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
D
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.
D Ne pas toucher des parties chaudes à mains nues
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
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, 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 Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables.
D Rester à l’écart des organes mobiles comme le
ventilateur.
D Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
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 dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un engin d’une capacité appropriée pour
soulever 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.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
D
D
D Prévoir une période de refroidissement, respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D Ne pas obstruer les passages d’air du poste.
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.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
D Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil
de soudage.
D Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de radio–navigation et de communication, les services
de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
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 et un blindage pour réduire les interférences éventuelles.
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.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-358 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
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.
OM-358 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – DEFINITIONS (CE Models Only)
2-1. Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1.3
2
1
1.1
1.2
1.3
2.1
2.2
2.3
2
2.1
2.2
2.3
3
3.1
3
3.1
3.2
3.2
3.3
3.3
4
4
4.1
+
5
+
+
4.1
6
+
5
6
S-179 310
Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.
OM-358 Page 9
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
2
1
2
4
3
5
V
V
> 60 s
V
3
4
5
6
S-185 836
7
6
9
8
7
8
9
1
1
2
3
∠ = <60 °
4
∠
5
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
Always wait 60 seconds after
power is turned off before
working on unit, OR
Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
Always wear long sleeves and
button your collar when
servicing unit.
After taking proper
precautions as shown,
connect power to unit.
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
Use a proper cart to move
unit.
Do not use one handle to lift
or support unit.
S-179 309-A
2
3
4
5
1/96
OM-358 Page 10
2-2. Manufacturer’s Rating Label For CE Products Only
. For label location
see Section 3-4.
ST-189 968-A
OM-358 Page 11
2-3. Symbols And Definitions
A
Amperes
Panel–Local
V
Volts
Input
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
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
Touch Start
(GTAW)
S
Seconds
Negative
I2
Rated Welding
Current
U2
Conventional Load
Voltage
I1eff
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)
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
Work
Electrode
Balance % EN
Time (AC GTAW)
Hz
Unit may be used
in environments
with increased
hazard of electric
shock
OM-358 Page 12
SECTION 3 – INSTALLATION
3-1. Specifications
A. For Multivoltage Units
Input Power
Rated Welding Output
Amperage
Range
Maximum
Open-Circuit
Voltage DC
250 A @ 30 Volts AC, 40%
Duty Cycle
Three Phase
200 A @ 28 Volts DC, 40%
Duty Cycle
5–300
95
250 A @ 30 Volts AC, 40%
Duty Cycle
Single Phase
5–300
95
200 A @ 28 Volts DC, 40%
Duty Cycle
Amperes Input at Rated Load Output 60 Hz
230 V
460 V
KVA
KW
26.3
*.27
17.9
*.15
14.2
*.09
10.5
*.04
20.5
*.27
13.4
*.15
8.4
*.09
7.6
*.04
62.6
*.33
32.2
*.18
14.8
*.10
10.4
*.07
44
*.33
25.8
*.18
11.9
*.1
8.1
*.07
*While idling
B. For Single Voltage Units
Rated Welding Output
Amperage Range
Maximum
Open-Circuit
Voltage DC
Amperes Input At Rated
Output, 50Hz - Three-Phase
400 V
KVA
KW
250 A @ 30 VAC,
40% Duty Cycle
5 – 300
95 VDC
20.2 (0.13*)
14.0 (0.09*)
10.5 (0.04*)
200 A @ 28 VDC,
40% Duty Cycle
5 – 300
95 VDC
15.1 (0.13*)
10.5 (0.09*)
7.5 (0.04*)
*While idling
3-2. Volt-Ampere Curves
Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall between curves shown.
SA-185 793 / SA-186 294
OM-358 Page 13
3-3. 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 5-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
250 A @ 40% Duty Cycle For AC
200 A @ 40% Duty Cycle For DC
4 Minutes Welding
6 Minutes Resting
Overheating
0
A or V
15
Minutes
OR
Reduce Duty Cycle
sduty1 5/95 / SA-185 794
OM-358 Page 14
3-4. Selecting a Location
1
Lifting Handles
Use handles to lift unit.
2
Dimensions And Weight
90 lb (40.7 kg) – 110 lb (50kg) w/aux power
Hand Cart
Use cart or similar device to move
unit.
24 in
(610 mm)
3
Rating Label (Non CE
Models)
Use rating label to determine input
power needs.
17 in
(432 mm)
4
5
Plate Label (CE Models)
Line Disconnect Device
Locate unit near correct input
power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
12-1/2 in
(318 mm)
Movement
Y Do not move or operate unit
where it could tip.
1
1
2
Location And Airflow
5
3
18 in
(460 mm)
4
18 in
(460 mm)
loc_2 3/96 - ST-802 135-A
OM-358 Page 15
3-5. 115 Volts AC Duplex Receptacle, Circuit Breaker CB1 (Optional), And Power Switch
1
AC Duplex Receptacle
1
115 V 10 A for 230/460 volt models.
115 V 7 A for 400 volt models.
2
2
3
Circuit Breaker CB1
CB1 protects duplex receptacle
from overload.
Press button to reset breaker.
3
Power On/Off Switch
ST-801 866-A
3-6. Weld Output Terminals and Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
Weld Output
Terminals
Work
Electrode
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 – 60%
Duty
Cycle
60 – 100%
Duty Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
10 – 100% Duty Cycle
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your
distributor for the mm2 equivalent weld cable sizes.
**Select weld cable size for pulsing application at peak amperage value.
NOTE: For proper installation of gas hose, the use of a quick connect torch (such as Weldcraft QWP-17 or QWP-20), is recommenced.
S-0007E
OM-358 Page 16
3-7. Remote 14 Receptacle Information
Socket*
Socket Information
ST-802 135-A
A
B
K
J
I
A
Contactor control, 24 volts dc.
B
Contact closure to A completes 24 volts dc
contactor control circuit, and enables output.
C
Output to remote control; 0 to +10 volts dc output
to remote control.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
F
Current feedback; +1 volt dc per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt dc per 10 output
receptacle volts.
GND
K
Chassis common.
24 VOLTS DC
H
C L N
D M
G
E F
REMOTE
OUTPUT
CONTROL
A/V
*The remaining sockets are not used.
OM-358 Page 17
3-8. Remote Program Select Inputs (Optional For Non CE Models)
10-Pin Receptacle RC2
Pin Designations
0=No Connection
1=Connected To Ground (Pin G)
Function
A
B
C
D
J
I
H
C
H
F
E
D
No Remote Control
0
0
0
X
X
Stick EP Of Current Program
1
0
0
X
X
Stick AC Of Current Program
1
1
0
x
x
TIG AC Of Current Program
0
1
0
x
x
Program 1 Stick EP
1
0
1
0
0
Program 2 Stick EP
1
0
1
0
1
Program 3 Stick EP
1
0
1
1
0
Program 4 Stick EP
1
0
1
1
1
Program 1 TIG EN
0
0
1
0
0
Program 2 TIG EN
0
0
1
0
1
Program 3 TIG EN
0
0
1
1
0
Program 4 TIG EN
0
0
1
1
1
Program 1 Stick AC
1
1
1
0
0
Program 2 Stick AC
1
1
1
0
1
Program 3 Stick AC
1
1
1
1
0
Program 4 Stick AC
1
1
1
1
1
Program 1 TIG AC
0
1
1
0
0
Program 2 TIG AC
0
1
1
0
1
Program 3 TIG AC
0
1
1
1
0
Program 4 TIG AC
0
1
1
1
1
G
F
E
ST-802 135-A
*The remaining sockets are not used.
Socket A
Contactor control, 24 volts dc
Socket B
Contact closure to A, completes 24 volts dc contactor
control circuit and enables output
Socket G
Chassis ground
Socket I
Normally open valid arc relay
Socket J
Circuit common for valid arc relay
To use the Remote Process Select function for a given program, select the TIG process on the front panel while the desired program
is selected.
OM-358 Page 18
3-9. Gas Connections
1
Gas Fitting
Fittings have 5/8-18 right-hand
threads.
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 cfh (cubic feet
per hour).
1
Connect customer supplied gas
hose between regulator/flowmeter
and gas fitting on rear of unit.
Tools Needed:
5/8, 1-1/8 in
ST-801 866
3-10. Electrical Service Guide
A. For Multivoltage Units
NOTE
Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.
Three-Phase
Input Voltage
Single-Phase
230
460
230
460
AC
26.5
17.9
62.6
32.2
DC
20.5
13.4
44
25.8
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
50
25
100
50
Min Input Conductor Size In AWG/Kcmil
10
14
8
10
104 (32)
165 (50)
90 (27)
241 (74)
10
14
8
10
Input Amperes At Rated Output
Max Recommended Input Conductor Length In Feet
(Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).
S-0092J
B. For Single Voltage Units
Input Voltage
400
Input Amperes At Rated Output
20.2
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
30
Min Input Conductor Size In AWG/Kcmil
14
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).
125 (38)
14
S-0092J
OM-358 Page 19
3-11. Connecting Input Power
Check input voltage available at
site.
1
2
Input And Grounding
Conductors
Line Disconnect Device
See Section 3-10.
For three-phase operation:
1
3
Y Always connect green or
green/yellow wire to supply
grounding terminal, never to
a line terminal.
Connect black, white, and red wires
(L1, L2, L3) to line terminals.
For single-phase operation:
2
Y Always connect green wire
to supply grounding terminal, never to a line terminal.
2
3
L1
L2
L3
4
5
6
L1
L2
Insulate and isolate red conductor
as shown.
Green Or
Green Or
Green/Yellow
Black And White Input
Conductor
Red Input Conductor
Insulation Sleeving
Electrical Tape
Green/Yellow
1
Y Always connect grounding
conductor first.
1
= GND/PE
1
3
4
Green Or
Green/Yellow
1
6
5
input_2 3/96 - ST-802 136-A
OM-358 Page 20
SECTION 4 – OPERATION
4-1. Controls
A. For 230/460 Volts And Non CE Units (Use With Section 4-2)
8
7
22
21
20
6
12
23
3
24
2
25
1
26
27
4
5
28
11
10
29
9
16
17
18
19
13
TIG Function Keys
14
15
Memory
Function
Keys
Stick Function Keys
30
Rear Panel
Ref. ST-188 477-A
OM-358 Page 21
B. For CE Units (Use With Section 4-2)
8
7
22
21
20
6
12
23
3
24
2
25
1
26
27
4
5
28
11
10
29
9
16
17
18
TIG Function Keys
19
13
14
15
Memory
Function
Keys
Stick Function Keys
30
Rear Panel
ST-186 714-A / Ref. ST-801 866
OM-358 Page 22
4-2. Description Of Controls (Use With Sections A And B)
. For all
front panel switch pad controls:
press switch pad to turn on light and enable
function.
1 Remote Trigger (Normal) Mode
See Section 4-3.
2 Remote Trigger (2T) Hold Mode
See Section 4-4.
3 4T Mode (Specific Trigger Method)
See Section 4-5.
To reconfigure 4T control for use as Spot, Contactor On Lift-Arc , and Mini Logic control, see
Section 4-6.
4 Lift-Arc Start Mode
See Section 4-10.
5 HF Start Mode
See Section 4-10.
6 Encoder Control
Use Encoder Control in conjunction with applicable front panel function switch pads to
change values for that function.
7 Ammeter
Displays amperage and preset parameters for
pulse frequency, % of background amperage,
% of dig, and % of peak time.
8 Voltmeter
Displays arc voltage and the following preset
times (preflow, initial slope, final slope, and
postflow) in seconds, for applicable function
controls.
9 Preflow Time Control
Press switch pad and turn Encoder Control to
set time, 0–15 seconds, gas flows before welding electrode is energized. Preflow control is
disabled if Lift-Arct Start mode is selected.
Application:
Preflow is used to purge the immediate weld
area of atmosphere. Preflow also aids in consistent arc starting.
10 Initial Amperage Control
Press switch pad and turn Encoder Control to
select a starting amperage, 5–300 amps, that
is different from the weld amperage.
Application:
Start current can be used while GTAW welding
to assist in preheating a cold material prior to
depositing filler material.
11 Initial Slope Time Control
Press switch pad and turn Encoder Control to
select length of time, 0–25 seconds, that it
takes to slope the amperage up/down from
start amperage to weld amperage.
12 TIG Weld Amps And Peak Amps When
Pulse Is Selected
Press switch pad and turn Encoder Control to
select 5–300 amps for TIG welding or peak
amps while pulsing.
13 Final Slope Time Control
Press switch pad and turn Encoder Control to
select length of time, 0–25 seconds, that it takes to slope the amperage up/down from weld
amperage to final amperage.
Application:
Final Slope Time 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.
Note: This applies if the operator is using an
on/off only type control to start and stop the
welding process.
14 Final Amperage Control
Press switch pad and turn Encoder Control to
select 5–300 amps of final amperage. Final
amperage is the amperage to which the weld
amperage has sloped up/down to.
15 Postflow Time Control
Press switch pad and turn Encoder Control to
set time, 0–50 seconds, 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
welds are dark in appearance.
16 Pulser On/Off Control
Press switch pad to turn on light and enable
pulser function.
Application:
Pulsing refers to the alternating raising and
lowering of the weld output at a specific rate.
The raised portions of the weld output are controlled in width, height, and frequency, forming
pulses of weld output. These pulses and the
lower amperage level between them (called the
background 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.
17 Pulse Frequency Control
Press switch pad and turn Encoder Control to
set pulse frequency, .1–500 pps (pulses per
second).
18 Pulse Width Control
Press switch pad and turn Encoder Control to
set percentage of time, 5–95%, amperage is at
peak for each pulse.
19 Background Amperage Control
Press switch pad and turn Encoder Control to
set background amperage as a percentage,
5–95%, of peak amperage.
20 AC TIG Process Select Mode
Press switch pad to select AC TIG Process.
21 AC Frequency Control
Press switch pad and turn Encoder Control to
set AC frequency from 20–250 Hz (cycles per
second). AC Frequency Control is enabled
only if AC TIG process is selected.
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.
22 AC Balance Control
Press switch pad and turn Encoder Control to
set percentage of time, 30–90%, polarity is
electrode negative. AC Balance Control is enabled only if AC TIG process is selected.
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.
Arc rectification can occur when welding above
200 amps and/or while welding with helium
gas. If this condition occurs, increasing the Balance control towards maximum penetration,
may help to restabilize the arc.
23 DC TIG Process Select Mode
Press switch pad to select DCEN (direct current electrode negative) TIG process.
24 1–4 Program Storage
Each program switch pad, 1–4, is capable of
storing four welding parameter programs. Four
for AC TIG, four for DCEN TIG, four for AC
Sick, and four for DCEP (direct current electrode positive) Stick. Depending on which process is selected, a total of 16 welding parameter programs can be recalled. The welding parameters are updated to the selected memory
position any time a parameter is changed. To
recall a program, press the desired process select switch pad, and program pad 1–4.
25 AC Stick Process Select Mode
Press switch pad to select AC Stick process.
AC frequency is fixed at 60 Hz, and AC balance
is fixed at 50% EN (electrode negative). When
the AC Stick Process is select, the DIG function is disabled.
26 DC Stick Process Select Mode
Press switch pad to select DCEP Stick process.
27 Output Contactor Control (Stick)
Press switch pad to enable/disable output.
28 Stick Amperage Control
Press switch pad and turn Encoder Control to
select 5–300 amps for Stick welding.
29 DIG Control
Press switch pad and adjust Encoder Control
to set DIG (0–100%).
When set lower, short-circuit amperage at low
arc voltage is the same as normal welding amperage.
When set higher, short-circuit amperage is increased at low arc voltage to help with arc starting and making overhead or vertical welds, as
well as to reduce sticking while welding.
30 Power On/Off Switch
Switch located on rear panel.
OM-358 Page 23
4-3.
Remote Trigger (Normal) Mode
1
1
Remote Switch Pad
Press switch pad to activate function.
Torch trigger operation is as shown.
NOTE: When a foot or finger remote
control is connected to the welding
power source, initial amps, initial
slope, final slope, and final amps are
not functional.
NOTE: Initial weld amperage and final amperage is controlled by the remote device, not by the welding
power source.
NOTE: If On/Off only type trigger is
used, it must be a maintained switch.
All functions become active.
Application: Use Remote Trigger
when the operator desires to use a
foot pedal or finger amperage control.
Current (A)
Torch Trigger Operation
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Foot Or Finger
Remote Control
OM-358 Page 24
Release For
Maintained Switch
Release Foot Or Finger Remote Control
4-4.
Remote Trigger (2T) Hold Mode
1
1
Remote Trigger Hold Switch
Pad
Press switch pad to activate function.
Torch trigger operation is as shown.
NOTE: When a foot or finger remote
control is connected to the welding
power source, only trigger input is
functional.
NOTE: Amperage is controlled by
the welding power source.
Application: Use Remote Trigger
Hold (2T) when long extended welds
are made. Remote Trigger Hold (2T)
can help to reduce operator fatigue.
Current (A)
Torch Trigger Operation
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release Trigger
In Less Than 3/4 Sec.
Push & Release Trigger
In Less Than 3/4 Sec.
NOTE: If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Normal) mode (see Section 4-3). If
arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 5-3).
OM-358 Page 25
4-5.
4T (Specific Trigger Method)
1
4T Switch Pad
Press switch pad to activate function.
1
Torch trigger operation is as shown.
While in 4T mode, there is a feature
available during the main weld sequence that allows the operator to
toggle between weld current and
final current without breaking the
arc.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by the
welding power source.
Application:
Use 4T 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
Weld Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Trigger
OM-358 Page 26
Release
Trigger
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger
Release
Trigger
4-6. Reconfiguring 4T For Mini Logic Control, Spot, Or Contactor On Lift-Arc
1
2
2
4T Switch Pad
Power Switch
To reconfigure 4T, push and hold 4T
switch pad and turn On power
switch. Hold switch pad for approximately 7 seconds (or until software
version number _ _ _ _ _ _-_clears,
and meters display [Ć--] [H-4]).
Rear Panel
3
3
Encoder Control
Use Encoder to change functions.
Active function will be displayed on
amperage (right) meter.
---
H-4
4
Meter Displays
Meter displays for the different functions will be as shown.
1
Press torch trigger or turn power Off
to save setting.
NOTE: Use 4T switch pad to access
the new configured functions.
Proceed to Section 4-7 for Mini Logic
operation.
Proceed to Section 4-8 for Spot Control Operation.
Proceed to Section 4-9 for Contactor
On Lift-Arc Operation.
---
H-4
---
H4L
=
4T (See Section 4-5)
=
Mini Logic (See Section 4-7)
4
---
SPO
=
Spot (See Section 4-8)
---
O-1
=
Lift-Arc
(See Section 4-9)
OM-358 Page 27
4-7. Mini Logic Operation
1
1
Mini Logic Meter Display
Select Mini Logic according to Section 4-6.
Torch trigger operation is as shown.
---
H4L
=
Mini Logic
During Mini Logic welding operation, the weld current can be manually changed from the initial amps
level to the main weld amps level by
pressing and releasing the torch
trigger in less than 3/4 seconds.
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.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.
Torch Trigger Operation
Current (A)
Weld Amps
Final Slope
Rate
Initial Slope
Final Slope
Start Amps
Initial Amps
Final Slope
Rate
Preflow
Push & Hold
Trigger
Push & Hold
Trigger For More
Than 3/4 Sec.
Release Trigger
OM-358 Page 28
Postflow
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger For More
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger For More
Than 3/4 Sec.
4-8. Spot Control Operation
1
1
2
3
---
Spot Function Meter Display
Select Spot function according to
Section 4-6.
3
SPO
=
Spot
TIG Weld Amps And Peak
Amps While Pulsing Switch
Pad
Encoder Control
Set spot parameters as follows:
Press switch pad once (amps LED
lights) and turn Encoder to set spot
amperage. Press switch pad again
(seconds LED lights) and turn Encoder to set spot time (.1–25 seconds).
Torch trigger operation is as shown.
NOTE: When a remote switch is
connected to the welding power
source, only trigger input is functional. Amperage is controlled by
the welding power source.
2
Application: To provide a timed
weld. Used for tacking, and thin
sheet joining.
Current (A)
Torch Trigger Operation
Timed Spot Weld Amps
Preflow
Push & Hold
Trigger
Postflow
Release
Trigger
NOTE: If arc is broken and trigger is depressed, or trigger is still depressed after postflow time is complete, HLP-10 will be
displayed (see Section 5-3).
OM-358 Page 29
4-9. Contactor On Lift-Arc Operation
1
Contactor On Lift-Arc Meter
Display
1
Select Contactor On Lift-Arc function according to Section 4-6.
Proceed to Section 4-10 Lift-Arc
start procedures.
---
O-1
=
Lift-Arc
Application: Lift-Arc is used for the
DCEN GTAW process when the HF
start method is not permitted, or to
replace the scratch start method.
Also, allows for the use of Lift-Arc
without a remote on/off switch.
NOTE: Preflow is a manual function and begins when the tungsten contacts the weldment. The length of time is determined by the
operator. Postflow is a timed function, and begins when the arc is manually broken.
4-10. Lift-Arct And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
1
“Touch”
1–2
Seconds
2
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point, enable output with torch trigger, foot control, or
hand control. Hold electrode to
workpiece for 1-2 seconds, and
slowly lift electrode. An arc will form
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
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.
Ref. ST-156 279
OM-358 Page 30
4-11. Programmable HF Start Amperage And Time Modes
A.
Accessing Programmable HF Start Amperage And Time Modes
NOTE: Before accessing programmable HF start amperage and time
modes, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while programmable HF start and
time modes are active.
1
2
2
Lift-Arc And HF Start Mode
Key Pads
Power Switch
To display the programmable HF
start amperage and time screens,
push and hold Lift-Arc and HF Start
switch pads and turn On power
switch. Hold switch pads for
approximately 7 seconds (or until
software version number _ _ _ _ _
_-_clears meters).
1
Proceed to Section B and/or C.
Rear Panel
B.
Setting Programmable HF Start Amperage
3
-5–
30
2
1
Or
NOTE: Before accessing programmable
HF start amperage mode, be sure that all
procedures and parameters are established. Parameter adjustment is limited
while programmable HF start amperage
mode is active.
Welding cycle can be executed while in
programmable start mode, but program parameters cannot be adjusted while in this
mode.
1
Initial Amps Switch Pad
2 Memory Program Switch Pads (1–4)
3 Encoder Control
To adjust DCEN or AC HF start amperage
proceed as follows:
Press desired TIG process switch pad (AC
TIG or DC TIG) to activate desired process
and turn On LED.
Press desired memory switch pad (1–4) to
activate desired memory program and turn
on LED.
Press Initial Amps switch pad. Switch pad
LED turns on, meter A LED turns on, and
[-5- ] [30 ] is displayed on meters.
The “30 ” displayed on the amps meter is
AC start amps and “20” is DC start amps
(these are factory default settings), and can
be adjusted from 1 to 200 amps by turning
the Encoder control.
To change start time, proceed to Section C.
To save changes to HF start amperage
without changing start time, select a different memory program number, or turn power Off.
OM-358 Page 31
C. Setting Programmable Start Time
3
-5-
20
2
1
Or
NOTE: Before accessing programmable
start time mode, be sure that all procedures
and parameters are established. Parameter adjustment is limited while programmable start time mode is active.
Welding cycle can be executed while in
programmable start mode, but program parameters cannot be adjusted while in this
mode.
1
2
Initial Slope Switch Pad
Memory Program Switch Pads (1–4)
OM-358 Page 32
3
Encoder Control
To adjust start time proceed as follows:
Press desired TIG process switch pad (AC
TIG or DC TIG) to activate desired process
and turn On LED.
If you are adjusting start time without having adjusted start amperage in Section B,
press desired memory switch pads (1–4) to
activate desired memory program and turn
on LED.
Press Initial Slope switch pad. Switch pad
LED turns on, meter S LED turns on, and
[-5- ] [20] is displayed on meters.
The [20 ] displayed on the amps meter is AC
start time, and [3 ] is DC start time (these are
factory default settings), and can be adjusted from 1 to 200 milliseconds by turning
the Encoder control.
To save changes, select a different
memory program number, or turn power
Off.
4-12. Arc Timer/Counter Display
1
2
To display the arc timer/counter,
push and hold Initial and Final Slope
control switch pads, and turn On
Power switch. Hold switch pads for
approximately 7 seconds (or until
software version number
_ _ _ _ _ _-_clears meters).
1
1
3
2
And
Arc Counter
456
999
999
Arc Counter
After 5 seconds, the meter A and
Memory 2 LEDs turn 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.
Rear Panel
123
Arc Timer Display
Upon power up as described
above, the meter S and Memory 1
LEDs will turn on, and arc time will
be displayed for 5 seconds as [000
000 ] to [999 999 ]. 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 Timer
Initial And Final Slope Control
Switch Pads
Power Switch
3
4
OM-358 Page 33
4-13. Lock Out Functions
A. Accessing Lock Out Capability
3
---
L-0
4
---
1
L-1
or 2,3,4
2
Rear Panel
See Section 4-1 for explanation of controls referred to in all of
Section 4-13.
There are four (1–4) different lock out levels. Each successive level
allows the operator more flexibility.
NOTE: Before activating lock out levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited
while lock out levels are active.
1 Memory Program Buttons 3 And 4
2 Power Switch
To access lock-out screens, press and hold memory program switch
pads 3 and 4, and turn On power switch. Hold switch pads for
approximately 7 seconds (or until software version number _ _ _ _
_ _-_clears meters).
3 Lock Out Off
If meter display is as shown, lockout feature is off.
4 Lock-Out On
If meter display is as shown, lockout feature is on.
To turn On the lock out feature, proceed as follows:
Enter a three digit code using the four Memory Program switch pads.
NOTE: If any switch pad other than a numbered Memory Program
OM-358 Page 34
switch pad is used, the lock out code is cancelled, and the lock out
condition will remain inactive.
Once three digits have been entered, the amperage screen display
will change from [L-0 ] to [L--- ].
There are four lock out levels available. Enter any single digit (1–4),
using the Memory Program switch pads, to access a lock out level
(see Sections B and/or A).
Press torch trigger or turn Off power to complete lock out On
sequence.
To turn Off the lock out feature, proceed as follows:
To access lock-out screens, press and hold memory program switch
pads 3 and 4, and turn On power switch. Hold switch pads for
approximately 7 seconds (or until software version number
_ _ _ _ _ _-_clears meters).
Enter the same three digits that were used to turn on the lock out feature. NOTE: If any switch pad other than a numbered Memory Program key pad is used, the code is cancelled, and the lock out condition will remain On.
Once the correct three digits have been entered, the amperage
screen display will change from [L-1 ] or 2,3,4 to [L-0 ].
Press torch trigger or turn Off power to complete lock out Off
sequence.
B. Lock Out Levels
Level 1
Level 1
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
NOTE: Remote amperage control
is not available in level 1.
Trigger Selection
Allows for normal, 2T, or 4T trigger
mode to be selected if the TIG process was selected when lock out
feature was activated.
Or
Or
Trigger Selection (TIG)
Contactor Control (Stick)
Stick Contactor Control
Allows for contactor control if the
Stick process was selected when
lock out feature was activated.
Level 2
Level 2
Select desired program
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
NOTE: Remote amperage control
is not available in level 2.
Includes all the functions of level 1
plus the following:
Program Selection
Program Selection 1–4
Gives operator the ability to select
desired program.
Process Selection – TIG or Stick
Gives operator the ability to select
between the TIG or Stick process,
and between AC or DC .
Or
Select TIG
or Stick
Lift-Arc Or HF Start Mode
Gives operator the ability to select
Lift-Arc or HF Start mode.
Process Selection
Or
Select Lift-Arc Or
HF Start mode
Lift-Arc Or HF Start Mode Selection
OM-358 Page 35
C. Lock Out Levels (Continued)
Level 3
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited while
lock out levels are active.
Level 3
Note: Remote amperage control is
not available in level 3.
Includes all the functions of levels 1
and 2 plus the following:
+/– 10% adjustment of preset TIG
Weld Amps or Peak Amps While
Pulsing or Stick Weld Amps
Select TIG or Stick
Amperage control,
and use Encoder to
adjust amperage.
Select desired amperage control
(TIG or Stick, and use Encoder control to adjust amperage +/– 10% of
preset amperage value, up to the
limits of the machine.
Pulser ON/Off Control
Gives operator the ability to turn on/
off the Pulser control.
Level 4
+/– 10 % Amperage Adjust Control
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited while
lock out levels are active.
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 3-7.
Turn Pulser control on/off
Pulser On/Off Control
Level 4
A
Remote Amperage Control
OM-358 Page 36
B
K
J
I
H
C L N
D M
G
E F
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace
unreadable
labels.
Replace damaged
gas hose.
Clean and
tighten weld
terminals.
Repair or replace cracked
cables and cords.
6 Months
Blow out inside. During heavy
service, clean monthly.
5-2. Blowing Out Inside of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
ST-802 135-A
OM-358 Page 37
5-3. Voltmeter/Ammeter Help Displays
V
A
0
V
A
HE.L
P-6
V
A
HE.L
P-7
V
A
HE.L
P-8
6
HE.L
P-0
V
A
1
7
HE.L
P-1
V
A
2
8
HE.L
P-2
V
A
V
A
HE.L
P-9
V
A
HE.L
P10
9
3
HE.L
P-3
V
A
4
10
HE.L
P-4
V
A
HE.L
P-5
5
. All directions are
in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
0 Help 0 Display
Indicates a short in the thermal protection
circuitry located on the left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
1 Help 1 Display
Indicates a malfunction in the primary power 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 left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
3 Help 3 Display
Indicates the left side of the unit has overheated. The unit has shut down to allow the
OM-358 Page 38
fan to cool it (see Section 3-3). Operation
will continue when the unit has cooled.
4
Help 4 Display
Indicates an open in the thermal protection
circuitry located on the right side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
5
Help 5 Display
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 3-3). Operation
will continue when the unit has cooled.
6
Help 6 Display
Indicates that the input voltage is too low
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (±10%). Have an
electrician check the input voltage if this display is shown.
7
Help 7 Display
Indicates that the input voltage is too high
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (±10%). Have an
electrician check the input voltage if this display is shown.
8
Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit. Contact a Factory
Authorized Service Agent if this display is
shown.
9
Help 9 Display
Indicates a short in the thermal protection
circuitry located on the right side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
10 Help 10 Display
Indicates torch trigger is depressed. Release trigger to continue.
5-4. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-11).
Check for proper input power connections (see Section 3-11).
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 Sections 4-1 and 3-7).
Input voltage outside acceptable range of variation (see Section 3-10).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-3).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 3-6).
Clean and tighten all weld connections.
No 115 volts ac output at duplex receptacle.
Reset circuit breaker CB1 (see Section 3-5).
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.
Use properly prepared tungsten.
Reduce gas flow rate.
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Increase postflow time.
Check and tighten all gas fittings.
Water in torch. Refer to torch manual.
OM-358 Page 39
SECTION 6 – ELECTRICAL DIAGRAM
Figure 5-1. Circuit Diagram For 230/460 Volt Models
OM-358 Page 40
SC-199 272
OM-358 Page 41
Figure 5-2. Circuit Diagram For 400 Volt Non-CE Models
OM-358 Page 42
SD-199 282
OM-358 Page 43
Figure 5-3. Circuit Diagram For 400 Volt CE Models
OM-358 Page 44
SD-199 280
OM-358 Page 45
SECTION 7 – HIGH FREQUENCY
7-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG – helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG
high_freq 12/96 – S-0693
7-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
5
6
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
OM-358 Page 46
7-3. Correct Installation
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
9
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Metal Building Requirements
9
Metal Building Panel Bonding Methods
Bolt or weld building panels together, install
copper straps or braided wire across seams,
and ground frame.
Ground water pipes every 50 ft (15 m).
10 Windows and Doorways
7
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
11 Overhead Door Track
Ground the track.
OM-358 Page 47
SECTION 8 – SELECTING AND PREPARING
TUNGSTEN ELECTRODE
gtaw 7/97
NOTE
For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.
8-1. Selecting Tungsten Electrode
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC – Argon – Electrode
Negative/Straight Polarity
DC – Argon – Electrode
Positive/Reverse Polarity
AC – Argon – Using
High Frequency
AC – Argon – Balanced
Wave Using High Freq.
.010”
Up to 25
*
Up to 20
Up to 15
.020”
15-40
*
15-35
5-20
.040”
25-85
*
20-80
20-60
1/16”
50-160
10-20
50-150
60-120
3/32”
135-235
15-30
130-250
100-180
2% Thorium Alloyed
Tungsten (Red Band)
1/8”
250-400
25-40
225-360
160-250
5/32”
400-500
40-55
300-450
200-320
3/16”
500-750
55-80
400-500
290-390
1/4”
750-1000
80-125
600-800
340-525
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
8-2. Safety Information About Tungsten
1
2
Y 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.
1
2
Tungsten Electrode With
Balled End
Pointed Tungsten Electrode
Ref. S-0161
Om-358 Page 48
8-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding
1
1
2
2
Tungsten Electrode
Tapered End
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.
2-1/2 Times
Electrode Diameter
1
2
3
1
2
Stable Arc
Flat
Diameter of this flat determines
amperage capacity.
3
4
Grinding Wheel
Straight Ground
1
2
3
4
Arc Wander
Point
Grinding Wheel
Radial Ground
4
Ideal Tungsten Preparation – Stable Arc
1
2
3
4
Wrong Tungsten Preparation – Wandering Arc
Ref. S-0161 / Ref. S-0162
OM-358 Page 49
SECTION 9 – GUIDELINES FOR TIG WELDING (GTAW)
9-1. Positioning The Torch
3
2
4
90°
1
Y 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
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 Sections 8-1 and 8-3.
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-358 Page 50
9-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
Tilt torch
Remove rod
15°
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
OM-358 Page 51
9-3. Positioning Torch Tungsten For Various Weld Joints
90°
Butt Weld And Stringer Bead
70°
20°
20°
“T” Joint
70°
10°
20°
40°
Lap Joint
70°
20°
30°
90°
Corner Joint
70°
20°
ST-162 003 / S-0792
Om-358 Page 52
Notes
OM-358 Page 53
SECTION 10 – PARTS LIST
46
. Hardware is common and
45
PC2
13
27
14
29
28
31
PC1
PC8
39
39
1
20
38
37
37
40
41
36
42
3
35
34
33
32
(Fig.10–2)–43
4
5
6
7
8
9
30–(PC3)
11
10
12
15
16
26
17
25
18
24
44
23
19
22
21
20
not available unless listed.
Figure 10-1. Main Assembly
OM-358 Page 54
ST-801 870-F
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
400
Non CE
Figure 10-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 195 585 . .
. . . 3 . . . . . . . . . . . . . 138 442 . .
. . . 3 . . . . . . . . . . . . . 179 309 . .
. . . 4 . . . . . . . . . . . . +175 148 . .
. . . . . . . . . . . . . . . . . . . 175 256 . .
. . . 5 . . . . . . . . . . . . . 134 327 . .
. . . 5 . . . . . . . . . . . . . 179 310 . .
. . . 6 . . . PC8 . . . . . 197 988 . .
. . . . . . . . PLG21 . . . . 115 094 . .
. . . . . . . . PLG22 . . . . 115 093 . .
. . . 7 . . . . . . . . . . . . . 183 613 . .
. . . 8 . . . . . . . . . . . . . 182 498 . .
. . . 9 . . . PC1 . . . . . 197 622 . .
. . . 9 . . . PC1 . . . . . 197 625 . .
. . . . . . . . PLG2 . . . . . 115 091 . .
. . . . . . . . PLG3 . . . . . 115 092 . .
. . . . . . . . PLG4 . . . . 131 054 . .
. . . . . . . . PLG5 . . . . . 115 091 . .
. . . . . . . . PLG7 . . . . 130 203 . .
. . . . . . . . PLG8 . . . . . 115 092 . .
. . . . . . . . PLG9 . . . . 131 204 . .
. . . . . . . . PLG10 . . . . 115 094 . .
. . . 10 . . . . T2 . . . . ♦193 311 . .
. . . 10 . . . . T2 . . . . ♦193 310 . .
. . . 11 . . . . . . . . . . . . ♦187 461 . .
. . . 12 . . . . T2 . . . . . 189 536 . .
. . . 12 . . . . T2 . . . . . 180 873 . .
. . . . . . . . RC10 . . . . 166 679 . .
. . . . . . . . PLG10 . . . 166 680 . .
. . . 13 . . . GS1 . . . . . 133 873 . .
. . . 14 . . . . . . . . . . . . ♦189 033 . .
. . . 15 . . . CB1 . . . . ♦083 432 . .
. . . 15 . . . CB1 . . . . ♦161 078 . .
. . . 16 . . . . . . . . . . . . . 605 227 . .
. . . 17 . . . . . . . . . . . . . 182 205 . .
. . . 18 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . ♦175 282
. . . 20 . . . . . . . . . . . . . 175 138
. . . 21 . . . . . . . . . . . . . 182 561
. . . 22 . . . . . . . . . . . . . 175 213
. . . 23 . . . . . . . . . . . . . 182 445
. . . 24 . . . . . . . . . . . . . 176 226
. . . 25 . . . . S1 . . . . . 128 756
. . . 26 . . . PC2 . . . . . 185 090
. . . . . . . . . . . . . . . . . . . 176 879
. . . . . . . . PLG13 . . . 131 204
. . . . . . . . PLG14 . . . . 115 094
. . . . . . . . . . . . . . . . . . . 179 626
. . . 27 . . . . . . . . . . . . +175 132
. . . 28 . . . . . . . . . . . . . 173 693
. . . 29 . . . . . . . . . . . . . 176 736
. . . 30 . . . PC3 . . . . . 190 364
. . . . . . . . DD1-6 . . . . 186 914
. . . . . . PLG17, 18 . . 131 054
HANDLE, rubberized carrying . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
LABEL, caution falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 2
LABEL, caution falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
INSULATOR, side RH & LH . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
LABEL, warning general precautionary . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 2
LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . 2
CIRCUIT CARD ASSEMBLY, clamp . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
INSULATOR, PC card clamp . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
BRACKET, mtg PC card clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . 1
CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . 1
BRACKET, mtg aux transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
VALVE, 24VDC 2way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
RECEPTACLE, str dx grd 2P 3W 15A . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
CIRCUIT BREAKER, 1P 10A 250VAC . . . . . . . . . . . . . . 1
CIRCUIT BREAKER, 1P 7A 250VAC . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
NUT, .750-14 knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
PLATE, identification rear
(order by model and serial number) . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . COVER, receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BOX, louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . . 2
. . CABLE, pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BUSHING, strain relief .472/.787 ID . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . NUT, stl locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . SWITCH, tgl 3PST 40A 600VAC (Power Switch) . . . . . 1 . . . . . 1 . . . . . 1
. . CIRCUIT CARD, assembly . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . SCREW, M5–.8–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . 18 . . . . 18
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BUS BAR, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4 . . . . . 4
. . SCREW, mtg foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4 . . . . . 4
. . CIRCUIT CARD, front panel (consisting of) . . . . . . . . . . 1 . . . . . 1 . . . . . 1
. . . . LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . 6 . . . . . 6
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1
OM-358 Page 55
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
400
Non CE
Figure 10-1. Main Assembly (Continued)
. . . . . . . . PLG26 . . . . 115 091
. . . . . . . . PLG11 . . . . . 115 092
. . . 31 . . . FM . . . . . 175 084
. . . . . . . . . . . . . . . . . . . 135 635
. . . 32 . . . . . . . . . . . . . 190 542
. . . 33 . . . . . . . . . . . . . 191 173
. . . 33 . . . . . . . . . . . . . 191 172
. . . 33 . . . . . . . . . . . . ♦191 172
. . . 34 . . . RC2 . . . . ♦191 302
. . . 34 . . . RC2 . . . . ♦191 302
. . . 35 . . . RC1 . . . . . 188 186
. . . 36 . . . . . . . . . . . . . 192 018
. . . 37 . . . . . . . . . . . . . 185 703
. . . 38 . . . . . . . . . . . . . 187 235
. . . 38 . . . . . . . . . . . . . 188 192
. . . 39 . . . C7,8 . . . . 186 543
. . . 40 . . . . . . . . . . . . . 186 446
. . . 40 . . . . . . . . . . . . . 189 229
. . . 41 . . . . . . . . . . . . . 186 952
. . . 42 . . . . . . . . . . . . . 190 543
. . . 43 . . . . . . . . . . . . . Fig 10-2
. . . 44 . . . . . . . . . . . . . 182 108
. . . 45 . . . . . . . . . . . . . 182 826
. . . 46 . . . . . . . . . . . . . 148 329
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CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
RECEPTACLE, w/leads & plug . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
NAMEPLATE, RH (order by model and serial number) 1 . . . . . 1
NAMEPLATE, RH (order by model and serial number) . . . . . . . . 1
NAMEPLATE, RH (order by model and serial number) 1 . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . .
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
NAMEPLATE, LH (order by model and serial number) . 1 . . . . . 1 . . . . .
RECEPTACLE, twist lock assembly . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
RECEPTACLE, female gas . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . .
RECEPTACLE, male gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
MEMBRANE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MEMBRANE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . .
KNOB, encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
CABLE, ribbon 24 posn 2.750 . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
WINDTUNNELS w/COMPONENTS . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LABEL, warning electric shock power cord . . . . . . . . . . . 1
LABEL, caution incorrect voltage . . . . . . . . . . . . . . . . . . . 1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Optional
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-358 Page 56
. Hardware is common and
not available unless listed.
3
1
38
4
11
5
2
10
6
7
8
12
9
16
13
14
15
38
37
36
35
17
34
18
33
31
32
30
19
20
21
29
22
38
23
28
27
24
26
25
ST-801 871-F
Figure 10-2. Windtunnels w/Components
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
400
Non CE
Figure 10-2. Windtunnels w/Components
(Fig 10-1 Item 43)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
. . . . . C11,12 . . . . 185 424
. . . . . C9,10 . . . . 164 812
. . . . . . HD1 . . . . . 182 918
. . . . . . . . . . . . . . . +182 206
. . . . . . . . . . . . . . . . 185 424
. . . . R1,C5,6 . . . 175 194
. . . . . . D1,2 . . . . . 185 775
. . . . . . . . . . . . . . . . 188 361
. . . . . . . . . . . . . . . . 182 208
. . . . . . . T3 . . . . . . 182 667
. . . . . . . . . . . . . . . . 183 073
. . . . . . . . . . . . . . . . 182 499
. . . . . . . . . . . . . . . . 182 806
. . . . . . C3,4 . . . . . 174 980
. . . . W1,2,2A . . . 175 082
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..
CAPACITOR, filter assembly . . . . . . . . . . . . . . . . . . . . 1 . . . . .
CAPACITOR, polyp met film 1MF 600 . . . . . . . . . . . . 2 . . . . .
TRANSDUCER, current 400A . . . . . . . . . . . . . . . . . . . 1 . . . . .
WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
CAPACITOR, filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
TRANSFORMER, coupling . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
INSULATOR, PC card HF . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
ENCLOSURE, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
BRACKET, mtg contactor/capacitor/PC board . . . . . 1 . . . . .
CAPACITOR, elctlt 2700uf 420VDC . . . . . . . . . . . . . . 2 . . . . .
CONTACTOR, def prp 40A 7P . . . . . . . . . . . . . . . . . . 1
1
2
1
1
2
1
1
2
1
1
1
1
1
2
.....
.....
.....
.....
1
2
1
1
.....
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1
1
2
1
1
1
1
1
2
OM-358 Page 57
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
400
Non CE
Figure 10-2. Windtunnels w/Components
(Fig 10-1 Item 43) (Continued)
. . . . . . . . . . . . . . . . . . . . . . 173 763
. . . 16 . . . . . . . T1 . . . . . . 183 014
. . . 17 . . . . . . . L2 . . . . . . 183 009
. . . 18 . . . . . . . L1 . . . . . . 187 522
. . . 19 . . . . . . PC9 . . . . . 187 264
. . . 20 . . . . . . . . . . . . . . . . 187 463
. . . 21 . . . . . . C1 . . . . . 186 549
. . . 22 . . . . . . . . . . . . . . . . 025 248
. . . 23 . . . . . . CT1 . . . . . 175 199
. . . 24 . . . . . . . . . . . . . . . . 177 547
. . . 25 . . . . . . . . . . . . . . . . 175 140
. . . 26 . . . . . . . . . . . . . . . . 181 197
. . . 27 . . . . . . L3,4 . . . . . 175 482
. . . 28 . . . . . . . . . . . . . . . . 109 056
. . . 29 . . . . . . . . . . . . . . . +187 460
. . . 30 . . . . . . . . . . . . . . . . 141 690
. . . 31 . . . . . . PC7 . . . . . 189 135
. . . . . . . . . . . . . F1 . . . . . . 012 633
. . . . . . . . . . . . . . . . . . . . . . 188 109
. . . . . . . . . . . PLG19 . . . . 115 092
. . . . . . . . . . . PLG20 . . . . 131 054
. . . 32 . . . . . . SR1 . . . . . 179 629
. . . 33 . . PM1,2/PC4,5 . 179 628
. . . . . . . . . . . RT1,2 . . . . 173 632
. . . 34 . . . . . . . . . . . . . . . . 173 631
. . . 35 . . . PM3,4/PC6 . . 185 776
. . . . . . . . . . . PLG23 . . . . 115 091
. . . 36 . . . . . . . . . . . . . . . . 182 641
. . . 37 . . . . . . . . . . . . . . . . 182 642
. . . 38 . . . . . . . . . . . . . . . . 185 835
. . . 38 . . . . . . . . . . . . . . . . 185 836
. . STAND-OFF, No. 10-32 x 1.418 lg . . . . . . . . . . . . . . . 7
. . TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . STABILIZER, output . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . CIRCUIT CARD ASSEMBLY, input filter . . . . . . . . . . . . . . . . . . 1
. . BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CAPACITOR, polyp .27uf 1000VDC . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . BUSHING, snap-in CT-mount . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . BRACKET, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . GASKET, DI-DT rubber . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . COIL, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . GROMMET, scr No. 8/10 . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4 . . . . .
. . CIRCUIT CARD, HF (consisting of) . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . . . FUSE, mintr gl 1A 250V . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . 2 . . . . . 2 . . . . .
. . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . KIT, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . BUS BAR, diode IGBT . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . BUS BAR, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . .
. . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . .
. . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . 2
1
1
1
1
2
1
1
1
1
2
2
1
4
1
1
2
1
1
1
1
2
1
1
1
1
1
2
+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-358 Page 58
Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
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.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts – 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
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.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers
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.
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 7/00
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
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate 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)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
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.
PRINTED IN USA
 2000 Miller Electric Mfg. Co.
6/00
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