Miller | MD026806D | Owner Manual | Miller HF 5000 CE User manual

Miller HF 5000 CE User manual
OM−235 241C
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
HF 5000
CE
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www.MillerWelds.com
OWNER’S MANUAL
2013−01
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
Miller Electric manufactures a full line of
welders and welding related equipment. For
information on other quality Miller products, contact your local Miller
distributor to receive the latest full line catalog or individual catalog sheets.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3-3. IP Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3-4. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3-6. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3-7. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3-8. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-9. Connecting Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-10. Rear Panel Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-11. Front Panel Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-12. Typical Connection To Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-13. Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-2. Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-3. Memory Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-4. Resetting Unit To Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-5. Selecting Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-6. 2T Or 4T Trigger Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-7. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-8. Pulse Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-9. Sequence Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-10. Lift-Arc And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-2. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-3. Temperature/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 7 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 8 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . . . 28
8-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter
Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that
the product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
HF 5000
V29012345
Council Directives:

2006/95/EC Low Voltage

2004/108/EC Electromagnetic Compatibility

2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:

IEC 60974­1 Arc Welding Equipment ­ Welding Power Sources: edition 3, 2005­07.

IEC 60974­3 Arc Welding Equipment – Arc Striking and Stabilizing Devices: edition 2.0, 2007­11.

IEC 60974­10 Arc Welding Equipment ­ Electromagnetic Compatibility Requirements: edition 2.0, 2007­08.

EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields
(0Hz­300Hz)
EU Signatory:
January 2nd , 2013
___________________________________________________________________________________
Massimigliano Lavarini
Date of Declaration
ELECTRONIC ENGINEER R&D TECH. SUPPORT
956 172 042
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-235 241 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-235 241 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
BATTERY EXPLOSION can injure.
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 Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
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 Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D
D
D
D
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-235 241 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures
in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-235 241 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
OM-235 241 Page 5
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
2-2. Miscellaneous Symbols And Definitions
A
V
Volts
Alternating Current
Protective Earth
(Ground)
Remote
On
Off
Single Phase
Line Connection
Water (Coolant) Input
Water (Coolant)
Output
Voltage Input
Increase
Decrease
HF Start (TIG)
Remote Standard
(2T Trigger Mode)
Remote
(4T Trigger Mode)
Lift-Arc (TIG)
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
Amperes
I1
Primary Current
U1
I2
Rated Welding
Current
Up
Voltage Peak
Duty Cycle
IP
Pulse
Hz
X
Gas Input
OM-235 241 Page 6
Primary Voltage
I1max
Rated Maximum
Supply Current
I1eff
Maximum Effective
Supply Current
Suitable For Areas
Of Increased
Shock Hazard
Set-Up
Degree Of
Protection
Circuit Breakers
Percent
Hertz
Read Instructions
Gas Output
Adjust
Recycle or Dispose of used
coolant in an environmentally safe
way
Note
t1
Gas Preflow Time
Ai
Amps Initial
t3
Initial Slope Time
Af
Amps Final
t2
Gas Postflow Time
Ab
Amps Background
t4
Final Slope Time
Notes
OM-235 241 Page 7
SECTION 3 − INSTALLATION
3-1. Important Information Regarding CE Products (Sold Within The EU)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
A. Information On Electromagnetic Fields (EMF)
3-2. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on cover of this manual.
3-3. IP Rating
IP Rating: 23S. This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless
sheltered.
Operating Temperature Range: 14 F (-10 C) to 104 F (40C). Ratings were developed at an ambient temperature of 20 C to 25 C.
3-4. Specifications
Type Of Input
Power
Welding Power Source
Type
115 Volts AC
Single-Phase
500mA
50/60 Hz
XMT 350/304/456 And
Standard Constant Current
Welding Power Source
OM-235 241 Page 8
Welding
Voltage
Range
Welding
Current
Range
Rated Welding Output
10-95 V
5-450 A
400 A @ 34 VDC,
100% Duty Cycle
Overall Dimensions
Length: 420 mm
Width: 250 mm
Height: 265mm
Weight
13 Kg
3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit or gun and void
warranty.
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
3-6. Selecting A Location
. Leave 500 mm free space on
sides with louvers.
(500 mm)
(500 mm)
956.142.654
3-7. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable
size.
OM-235 241 Page 9
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn,
damaged,
undersized, or poorly
spliced cables.
30 m (100 ft) or Less
60 m
(200 ft)
70 m
(250 ft)
90 m
(300 ft)
105 m
(350 ft)
120 m
(400 ft)
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
mm2 (AWG)
mm2 (AWG)
100
20 (4)
20 (4)
20 (4)
30 (3)
35 (2)
50 (1)
60 (1/0)
60 (1/0)
150
30 (3)
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
95 (3/0)
200
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
120 (4/0)
250
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
2x70
(2 ea. 2/0) (2 ea. 2/0)
300
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
2x95
2x95
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 3/0)
350
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
2x95
2x95
2x120
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 3/0) (2 ea. 4/0)
400
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
2x95
2x120
2x120
(2 ea. 2/0) (2 ea. 3/0) (2 ea. 4/0) (2 ea. 4/0)
Welding
Amperes
* This
45 m
(150 ft)
10 − 100% Duty Cycle
mm2 (AWG)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***For distances longer than those shown in this guide, call a factory applications representative.
OM-235 241 Page 10
Milan Ref. S-0007-G 2009−08
3-8. Installing Gas Supply
1
Cylinder valve
Remove cap, stand to side of
valve, and open valve slightly.
Gas flow blows dust and dirt
from valve. Close valve.
2
2
3
1
Regulator/Flowmeter
Install so face is vertical.
3
Flow Adjust
Typical flow rate is 15 CFH
(cubic feet per hour) (4.5 L/
hr).
Make sure flow adjust is
closed when opening cylinder
to avoid damage to the flowmeter.
4
Gas Input Fitting
Connect hose from shielding
gas supply regulator/flowmeter to gas in fitting. Fitting has
5/8-18 right-hand threads.
5
Gas Output Fitting
Connect shielding gas hose
from torch to gas out fitting.
Fitting has 3/8−19 BSPP
right-hand threads.
4
Tools Needed:
18 mm (11/16 in.)
5
956.142.654
3-9. Connecting Remote Control
1. Remote 14 Receptacle
2. Keyway
3. Plug
4. Threaded Collar
To connect to receptacle,
align keyway, insert plug,
and tighten threaded collar.
2
B
C
4
1
AJ
K
I
3
D
L
N H
M
E
G
Socket*
F
A
AMPERAGE
Socket Information
A
Remote control circuit common.
B
Contact closure to A completes trigger control
circuit.
C
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.
*The remaining sockets are not used.
OM-235 241 Page 11
3-10. Rear Panel Receptacle Information
!
Turn power off before making
connections.
1
Coolant Out Connection
Connect coolant return hose to coolant
out fitting.
2
Coolant In Connection
Connect coolant supply hose to
coolant in fitting.
8
3
Gas Input Connector
Connect gas supply hose to gas input
fitting (see Section 3-8).
4
7
6
4
115 V Input Power Cord
5
14-Pin Receptacle
Make connections between receptacle and matching receptacle on welding power source.
6
Positive (+) Input Receptacle
Connect cable from positive weld output terminal of welding power source.
1
2
3
7
Negative (−) Input Receptacle
Connect cable from negative weld output terminal of welding power source.
5
8
Supplementary Protector CB1
CB1 protects unit from overload.
956.142.656
3-11. Front Panel Receptacle Information
!
Turn power off before making
connections.
1
On/Off Switch
Use switch to turn unit on and off.
2
1
Remote 14-Pin Receptacle
Make connections
Section 3-9.
3
according
to
Coolant In Connection
Connect torch return hose to coolant in
fitting.
2
4
5
7
3
Coolant Out Connection
Connect torch supply hose to coolant
out fitting.
Gas Out Connection (See
Section 3-8)
Connect torch supply hose to gas out
fitting.
6
Negative (−) Output Receptacle
Connect TIG torch when TIG welding,
or work cable when Stick welding.
6
5
4
7
Positive (+) Output Receptacle
Connect work cable when TIG welding, or electrode holder when Stick
welding.
956.142.656
OM-235 241 Page 12
3-12. Typical Connection To Power Source
1
2
1
HF 5000
2
Welding Power Source
3
Cooling System
4
Typical Interconnecting Cable
!
Size power cables within the
interconnecting cable for
the required welding current and duty cycle (see Section 3-7). See welding power
source Owner’s Manual, and
following all applicable
codes when selecting cable
sizes.
Make interconnecting cable connections as follows:
 Connect negative weld cable to
negative weld receptacle on
power supply
 Connect negative weld cable to
negative weld terminal on unit
 Connect positive weld cable to
positive weld receptacle on
power supply
3
 Connect positive weld cable to
positive weld terminal on unit
 Connect 14-pin plug to 14-pin receptacle on power supply.
 Connect 14-pin plug to 14-pin receptacle on rear panel of unit.
 Connect gas supply hose to gas
supply. See section 3-8.
 Connect gas supply hose to gas
in connection. See section 3-10.
 Connect coolant supply hose to
coolant out fitting on coolant recirculating system.
4
 Connect coolant supply hose to
coolant in fitting on unit.
 Connect coolant return hose to
coolant in fitting on coolant recirculating system.
 Connect coolant return hose to
coolant out fitting on unit.
956.142.654 / 956. 142..656 / 803 691 / 956.142.653
3-13. Input Power Connection
1
Input Power Cord
Be sure the power source can
supply the 115 VAC necessary to power this unit.
1
956.142.654
OM-235 241 Page 13
SECTION 4 − OPERATION
4-1. Front Panel Controls
1
Power (On/Off )Switch
Use switch to turn unit on/off. Upon
power up, unit will recall and display
the last welding procedure, or factory default procedure.
The display on the unit will show
STCK if Stick was selected last.
The display on the unit will show 2T
or 4T if TIG welding.
2T or 4T trigger mode will display
based on last selection.
STCK, 2T, and/or 4T will display for
5 seconds, and then display preset
amperage.
2
9
1
Displays actual amperage while
welding. Meter also displays preset
parameters for any of the following
variables: time, frequency function,
setup.
3
8
2
7
Ammeter And Parameter
Display
Process Control Adjust
Use control to select welding process and light corresponding LED.
Control is also used for initial setup,
memory setting, and recalling factory parameters.
4
Setup Control
Use control to change selected
parameter, as indicated by lit LED,
for either the Standard TIG or TIG
Pulse process.
5
3
Decrease Control
Use control to reduce value shown
on display.
6
Increase Control
Use control to increase value
shown on display.
7
Process Indicator LEDs
LEDs show the selected welding
process.
4
5
6
8
Pulse Parameter Indicator
LEDs
9
Sequence Indicator LEDs
LEDs show the TIG parameter selected.
956.142.656
OM-235 241 Page 14
4-2. Initial Setup
1
2
3
4
5
6
6
Process Control Adjust
Setup Control
Decrease Control
Increase Control
Ammeter And Parameter
Display
Power Switch
To enter Initial Setup, turn power off.
Press and hold Increase and
Decrease controls and turn power
on. Continue to hold Increase and
Decrease controls until software
version clears display, and display
begins to flash, release Increase
and Decrease controls.
Upon power up TIG HF and Pulse
LEDs turn on, and the factory default of 400 flashes on the display.
5
Press the Setup control to scroll
through the following: power source
current range, current reading display, and TIG starting current.
Setting Power Source Current
Range:
Setting Maximum Amperage −
While display is flashing, press the
Increase and decrease controls until amperage shown on display
matches the maximum value of the
welding power source (see welding
power source Owner’s Manual).
Maximum amperage range is 200 to
600 amps, with 400 amps being the
default.
1
Press Setup control to confirm setting and continue Initial Setup.
2
3
4
Setting Minimum Amperage − While
display is flashing, press the Increase and decrease controls until
amperage shown on display
matches the minimum value of the
welding power source (see welding
power source Owner’s Manual).
Minimum amperage range is 5 to
200 amps, with 20 amps being the
default.
Press Setup control to confirm setting and continue Initial Setup.
Setting Current Display Reading:
While display is flashing, press the
Increase and Decrease controls to
select CURR or NOCU (CURR is
the default). CURR is actual current
output of the power source. NOCU
is the percentage of the current output of the power source.
Press Setup control to confirm setting and continue Initial Setup.
Setting TIG Starting Current:
While display is flashing, press the
Increase and Decrease controls to
set the TIG start current. The start
current range is 10 to 200 amps, 20
amps is the default.
Press Setup control to confirm setting
Turn power off to exit Initial Setup.
956.142.656
OM-235 241 Page 15
4-3. Memory Control
6
5
1
2
3
. The first three alphanumeric digits of
4
. All memory positions are empty when
ory parameters is performed (see Section 4-4).
1 Process Control
Use control to enter memory control and
confirm selected action.
2 Setup Control
Use control to exit memory control.
3 Decrease Control
Use control to scroll through the desired actions required for the selected memory positions, LOA, STO, and DEL.
4 Increase Control
Use control to scroll through memory positions 0−9.
5 Ammeter And Parameter Display
6 Power Switch
To create or change a welding parameter memory position, proceed as follows:
. Document all welding parameters for
Select desired process, Stick, TIG Lift, TIG
Lift Pulse, TIG HF, TIG HF Pulse.
the display indicate the desired action
being requested for the selected
memory position.
. The fourth alphanumeric digit of the dis-
play shows the selected memory position. If the fourth digit is −, than the requested action is not valid for the selected memory position.
LOA − Loads the welding parameters previously stored by the operator from the specified memory position.
STO − Stores welding parameters set by
the operator to an operator specified
memory position.
DEL − Permanently deletes stored welding
parameters from a specified memory position.
machine leaves factory
each memory position.
. Welding parameter data is stored until
intentionally deleted, or a recall of fact-
Set or modify all desired parameters.
With power on, press and hold Process
control until LOA is displayed .
Press and hold Decrease control until STO
is displayed.
Press Increase control to select desired
memory position 0−9.
Press Process control until OK is displayed.
To Recall a welding parameter memory
position, proceed as follows:
Press and hold Process control until LOA is
displayed .
Press Increase control to select desired
memory position 0−9.
Press Process control until OK is displayed.
To delete welding parameters from a
memory position, proceed as follows:
Press and hold Process control until LOA is
displayed .
Press and hold Decrease control until DEL
is displayed.
Press Increase control to select desired
memory position 0−9.
Press and release Setup control to exit
memory control.
956.142.656
OM-235 241 Page 16
4-4. Resetting Unit To Factory Default Settings
. Document
all welding
parameters for each
memory position.
. This procedure will delete
all operator specified
parameters, and recall all
factory parameters..
4
3
1
2
3
4
Process Control
Increase Control
Ammeter And Parameter
Display
Power Switch
Turn unit off. Press and holding the Process and Increase
controls, turn unit on, wait for
CLR to display before releasing controls.
1
2
956.142.656
4-5. Selecting Remote Control
. Document
all welding
parameters for each
memory position.
1
2
3
4
5
5
4
Setup Control
Decrease Control
Increase Control
Ammeter And Parameter
Display
Power Switch
Turn unit on. Press and hold
Setup control until INT or EXT
is displayed. Press Increase
or Decrease controls to
change between INT and
EXT.
Press Setup control, and OK
will display.
INT − indicates weld sequence is initiated when electrode makes contact with
workpiece. INT should be
used for Stick, TIG Lift, and
TIG Lift with pulse only
EXT − indicates weld sequence is initiated with some
external type of remote control.
1
2
3
956.142.656
OM-235 241 Page 17
4-6. 2T Or 4T Trigger Mode Selection
. Document
all welding
parameters for each
memory position.
1
2
3
4
5
Process Control
Decrease Control
Increase Control
Ammeter And Parameter
Display
Power Switch
5
Turn unit on. When welding
with any TIG process, the unit
will first display 2T of 4T.
4
To change between 2T and
4T, press the Process control
and 2T or 4T will display.
Press the Increase or
Decrease control to change,
after 5 seconds, weld amperage is displayed. Resume
welding.
1
2
3
Current (A)
Remote 2T Trigger Operation
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P
R
Remote 4T Trigger Operation
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P
R
P&R = Push and release trigger.
OM-235 241 Page 18
P
R
956.142.656
4-7. Process Control
1
2
3
Ammeter And Parameter
Display
Process Control
Process LEDs
Press Process control until
desired process LED or combination of LEDs are illuminated:
L1 − Stick welding (SMAW)
L2 − TIG Lift Start − when selected, is an arc starting method in which the electrode must
come in contact with the workpiece to initiate an arc ( see
Section 4-10).
3
1
L3 − TIG HF Start − When selected,
a
pulsed
HF
(non-contact) (see Section
4-10) arc starting method is
activated.
L4 − TIG Pulse Welding can
be used in combination with
L2 or L3. Pulsing is available
only while a TIG process is
active.
Press Process control to
scroll through the possible
process selections indicated
by the LED or LED combinations being illuminated:
2
L1 − Stick Welding
L2 − TIG Lift Start
L2 And L4 − TIG Lift Start with
Pulse
L3 − TIG HF Start
L1
L3 And L4 − TIG HF Start with
pulse.
Return to top.
L2
L3
L4
956.142.656
OM-235 241 Page 19
4-8. Pulse Control
. Pulse
welding is only
available while using the
TIG process.
1
5
1
Pulse Control LEDs
2
Setup Control
3
Decrease Control
4
Increase Control
5
Ammeter And Parameter
Display
While pulse welding, the current is alternating between a
peak current (A) and a background current (Ab), with a
defined percent (%) of peak
current, and a defined frequency (Hz). Full control of
these parameters gives the
operator better control of penetration, bead width, heat input, crowning, and undercutting.
Press Setup control to select
desired parameter, indicated
by illuminated LED.
Use the Increase/Decrease
controls to change value of
selected pulse parameter.
2
3
4
Peak Current (A) controls
weld penetration, and the min/
max values were established
during Initial Setup (see Section 4-2).
Pulse Frequency (Hz) controls weld bead appearance.
Minimum value is 0.1 Hz,
Maximum value is 10 or 500
Hz, the default is 10 Hz. Maximum pulse frequency is determined by type of power
source. Thyristor, engine driven, and old inverter power
sources are capable of only a
10 Hz maximum, while newer
inverters may be capable of
up to 500 Hz.
Background Current (Ab)
controls heat input, and the
min/max values were established during Initial Setup (see
Section 4-2).
Duty Cycle (%) controls weld
puddle cooling. The minimum
value is 5%, the maximum
value is 95%, and the default
is 50%.
956.142.656
OM-235 241 Page 20
4-9. Sequence Control
. Sequencing is only available while using
a TIG process.
1
Sequence LEDs
Sequencing is available only while using the
TIG process, but is disabled if a remote foot
or finger current control is connected to the
remote receptacle. Sequencer parameters
cannot be selected if the stick process is active.
1
2
Setup Control
Press setup control to select desired parameter, and illuminate corresponding LED.
5
3
Decrease Control
4
Increase Control
Press increase or decrease control to set
appropriate value for active sequence parameter. Value selected is shown on the ammeter.
5
Ammeter And Parameter Display
Pre Gas Time (t1) − Use control to set the
length of time gas flows before arc initiation.
Default = 0.2s (MIN = 0.0s, MAX = 25.0s).
Initial Current (Ai) − Use control to set the
current level that the arc will be established
with. Default = 10A (MIN = 5A or minimum
value set during initial setup, MAX = 500A or
maximum value set during initial set up).
2
3
4
Slope Up Time (t3) − Use control to set the
rate that current will rise from Initial to Weld
current. Default = 0.0s (MIN = 0.0s, MAX =
25.0s).
Weld Current (A) − Use control to set the
maximum Welding Current. Default = 100A
(MIN = 5A, MAX = 500A or maximum value
set during initial set up).
Slope Down Time (t4) − Use control to set
the rate that current will decrease from Weld
current to Final Current. Default = 0.0s (MIN
= 0.0s, MAX = 25.0s).
Final Current (Af) − Use control to set the
current level that the arc will finish with. Default = 10A ( MIN = 5A or minimum value set
during initial setup, MAX = 500A or maximum value set during initial set up).
Post Gas Time (t2) − Use control to set the
length of time gas flows after welding to protect the weld pool. Default = 10.0s (MIN =
0.0s, MAX = 50.0s).
956.142.656
OM-235 241 Page 21
4-10. Lift-Arc And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On, start arc as
follows:
Lift-Arc Start Method
1
“Touch”
1−2
Seconds
2
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start
point, enable output and shielding gas with torch
trigger, foot control, or hand control. Hold electrode
to workpiece for 1-2 seconds, and slowly lift electrode. Arc is formed when electrode is lifted.
Normal open-circuit voltage is not present before
tungsten electrode touches workpiece; only a low
sensing voltage is present between electrode and
workpiece. The solid-state output contactor does
not energize until after electrode is touching workpiece. This allows electrode to touch workpiece
without overheating, sticking, or getting
contaminated.
Application:
Lift-Arc is used for the DCEN or AC GTAW process
when HF Start method is not permitted, or to replace
the scratch method.
Do NOT Strike Like A Match!
HF Start
When HF Start button light is On, start arc as
follows:
High frequency turns on to help start arc when output is enabled. High frequency turns off when arc is
started, and turns on whenever arc is broken to help
restart arc.
Application:
HF start is used for the DCEN GTAW process when
a non-contact arc starting method is required.
OM-235 241 Page 22
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
!
Disconnect power before maintaining.
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
= Repair
l = Replace
Every
3
Months
nl Labels
~ Weld Terminals
n l Gas Hoses
Every
3
Months
n lCables And Cords
Every
6
Months
Do not remove case when blowing
out inside of unit. During heavy
service, clean monthly.
~:Durning heavy service, clean monthly.
5-2. Troubleshooting Table
Trouble
Display On, fan does not start.
Remedy
Check input power connection.
Turn power source on.
Check interconnecting cable and connectors, and tighten ring nuts on both sides.
Check power source 14-pin outputs.
Fan does not start, display on.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Parameters setting is not possible.
Check process selection, and change selection if necessary.
Switch unit off and on to reset factory parameters.
Re-program incorrect initial setup.
Current reading on unit exceeds maxim- Set correct current on welding power source.
um by more than five percent.
Have Factory Authorized Service Agent check current signal from welding power source.
OM-235 241 Page 23
Trouble
Remedy
Lack of HF, difficult arc starting. Unstable Prevent torch cables from contacting work circuit.
arc starts.
Repair or replace damaged or broken torch or cables.
Use correct size and/or type of tungsten electrode.
Have Factory Authorized Service Agent check control board PC1.
Arc unstable or difficult to control.
Use correct size and/or type of tungsten electrode.
Check for loose connections or worn parts (see Section 5-1).
Tungsten electrode oxidizing and not Prevent contact with filler wire or workpiece while welding.
clean after completion of weld.
Check all gas fittings for loose or poor connections.
Increase gas flow rate.
5-3. Temperature/Ammeter Help Displays
1
Display Screen
 HLP 1 Display
1
Indicates 500 amps has been
exceeded for 5 seconds.
 HLP 2 Display
Indicates an open/shorted thermistor.
 HLP 3 Display
Indicates an over temperature
condition.
 HLP 0 Display
Indicates a ground fault.
956.142.656
OM-235 241 Page 24
SECTION 6 − ELECTRICAL DIAGRAMS
956.142.624
Figure 6-1. Circuit Diagram
OM-235 241 Page 25
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 5/10 − S-0693
7-2. Installation Showing Possible Sources Of HF Interference
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
5
6
Best Practices
Not Followed
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
OM-235 241 Page 26
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
7-3. Recommended Installation To Reduce HF Interference
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece if
required by
codes.
9
Best Practices Followed
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case (clean paint
from around hole in case, and use case
screw), work output terminal, line disconnect device, input supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
OM-235 241 Page 27
SECTION 8 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2011-06
Whenever possible and practical, use DC weld output instead of AC weld output.
8-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
Amperage Range - Gas Type - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (1 mm)
Up to 25
Up to 20
.020 in. (1 mm)
15-40
15-35
.040 in. (1 mm)
25-85
20-80
1/16 in. (1.6 mm)
50-160
50-150
3/32 in. (2.4 mm)
130-250
135-235
1/8 in. (3.2 mm)
250-400
225-360
5/32 in. (4.0 mm)
400-500
300-450
3/16 in (4.8 mm)
500-750
400-500
1/4 in. (6.4 mm)
750-1000
600-800
Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
8-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC
Welding With Inverter Machines
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
Radial Grinding
Causes Wandering Arc
2-1/2 Times
Electrode Diameter
1
3
2
1
Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
2
Tungsten Electrode
A 2% ceriated tungsten is recommended.
Wrong Tungsten
Preparation
4
Ideal Tungsten Preparation − Stable Arc
3
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
OM-235 241 Page 28
SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW)
9-1. Positioning The Torch
!
Grinding the tungsten electrode
produces dust and flying sparks
which can cause injury and start
fires. Use local exhaust (forced
ventilation) at the grinder or wear
an approved respirator. Read
MSDS for safety information.
Consider using cerium or lanthanum based tungsten instead of
thoriated. Thorium dust contains
low-level radioactive material.
Properly dispose of grinder dust
in an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
1
Workpiece
3
2
4
90
Make sure workpiece is clean before
welding.
1
2
Work Clamp
Place as close to the weld as possible.
3
4
5
6
10−15
4
5
6
10−25
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten according
to Section 8.
Guidelines:
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate
shielding gas coverage. (For example,
if tungsten is 1/16 in. diameter, gas cup
should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the
tungsten extends out gas cup of torch.
1/16 in.
3/16 in.
Bottom View Of Gas Cup
The tungsten extension should be no
greater than the inside diameter of the
gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
OM-235 241 Page 29
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
15
Tilt torch
Remove rod
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
9-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20
90
70
75
20
10
15
Corner Joint
Lap Joint
20-40
90
75
75
15
15
30
ST-162 003 / S-0792
OM-235 241 Page 30
Notes
SECTION 10 − PARTS LIST
. Hardware
1
is common and
not available unless listed.
2
3
4
5
6
39
45
44
38
43
37
36
42
41
7
8
40
35
9
34
33
10
11
12
32
31
13
30
29
14
28
27
26
25
24
15
23
16
22
17
21
18
19
20
Figure 10-1. Main Assembly
OM-235 241 Page 32
956.142.655-A
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 10-1. Main Assembly
1 . . . . . . . . . . . . . . . 000208015 . . . . Handle Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . V56121323 . . . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . V56075245 . . . . HF Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . . . . . . . . V58021244 . . . . XFMR HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . . . 219343 . . . . Thermistor, NTC 30K Ohm11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . . . . . . . V56003325 . . . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . V56006321 . . . . Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . . . . . . . . V56039324 . . . . Box, PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 . . . . . . . . . . . . . . . 057084135 . . . . PCB, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . . . . . . . . 356031004 . . . . Bus Bar, LEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . . . . . 182918 . . . . Transducer, Current 400A Moduyle Supply V+/−15 . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . . 056067262 . . . . Circuit Breaker, Man Reset 1P 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . V56029326 . . . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
14 . . . . . . . . . . . . . . 000208967 . . . . Dinse 50, Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
15 . . . . . . . . . . . . . . 756007013 . . . . Cover, Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16 . . . . . . . . . . . . . . 056067251 . . . . Switch, Power On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . . . . . . . . . 000188192 . . . . Receptacle, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . . . . . . . . . . 556049402 . . . . Water Connection, Quick Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
19 . . . . . . . . . . . . . . 556049401 . . . . Water Connection, Quick Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20 . . . . . . . . . . . . . . 056076170 . . . . Receptacle, 14-Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21 . . . . . . . . . . . . . V56006320 . . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22 . . . . . . . . . . . . . . 656026120 . . . . Hose, 5x8,5x270 Black Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23 . . . . . . . . . . . . . . 000228036 . . . . Valve, 24VAC 1 Way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24 . . . . . . . . . . . . . . 000134306 . . . . Foot, Rubber Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
25 . . . . . . . . . . . . . . . . . 220805 . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
26 . . . . . . . . . . . . . . 656026121 . . . . Hose, 6x11x320 Red Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
27 . . . . . . . . . . . . . . 656026122 . . . . Hose, 6x11x320 Blue Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
28 . . . . . . . . . . . . . . 156033034 . . . . 3/8”−27 Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
29 . . . . . . . . . . . . . V56029347 . . . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
30 . . . . . . . . . . . . . . 556049403 . . . . Water Connection, Quick Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
31 . . . . . . . . . . . . . . 556049404 . . . . Water Connection, Quick Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
32 . . . . . . . . . . . . . . 027112306 . . . . Plug, Primary, Duplex 3-Pin 115 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
33 . . . . . . . . . . . . . . 656089038 . . . . Strain Relief, Primary Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
34 . . . . . . . . . . . . . . . 56076192 . . . . Receptacle, 14-Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
35 . . . . . . . . . . . . . . 056076216 . . . . Receptacle, Dinse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
36 . . . . . . . . . . . . . V56005322 . . . . Fan Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
37 . . . . . . . . . . . . . V56126035 . . . . Fan Assy, 115 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
38 . . . . . . . . . . . . . V58021336 . . . . XFMR, Toroid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
39 . . . . . . . . . . . . . V57084349 . . . . PCB, Trigger − Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
40 . . . . . . . . . . . . . . 058066057 . . . . GAS, connection kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
41 . . . . . . . . . . . . . . 057052043 . . . . Adapter 5/8 UNC−3/8 BSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
42 . . . . . . . . . . . . . . 057052044 . . . . Fitting, Hose Brs Barbed M 1/4tbg x 5/8−18 SAE . . . . . . . . . . . . . . . . . . . 1
43 . . . . . . . . . . . . . . 156018115 . . . . Nut 5/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
44 . . . . . . . . . . . . . . 057052045 . . . . Fitting, Quick Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
45 . . . . . . . . . . . . . . . . . 193440 . . . . Ground Fault Seneor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts.
Model and serial number required when ordering parts from your local distributor.
OM-235 241 Page 33
Notes
TM-216 869 Page 34
Dynasty 350/700, Maxstar 350/700
Effective January 1, 2013
(Equipment with a serial number preface of MD or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, ITW Welding Products Italy warrants to its original retail
purchaser that new Miller equipment sold after the effective date
of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser or one
year after the equipment is shipped to a European distributor or
eighteen months after the equipment is shipped to an
International distributor.
1.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Auto-Darkening Helmet Lenses (No Labor)
Migmatic 175
HF Units
Water
Coolant
Systems
(EU
Models,
Non-Integrated)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
5.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
Inverter Power Sources (Unless Otherwise Stated)
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Transformer/Rectifier Power Sources
Water Coolant System (Integrated)
2 Years — Parts
*
*
*
*
4.
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules with
exclusion of STR, Si, STi, STH and MPi series.
Automatic Motion Devices
Field Options
(NOTE: Field options are covered under True Blue
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Powered Air Purifying Respirator (PAPR) Blower
Unit (No Labor)
Racks
Running Gear and Trailers
Subarc Wire Drive Assemblies
Water
Coolant
Systems
(USA
Models,
Non-Integrated)
Work Stations/Weld Tables (No Labor)
6 Months — Parts
*
Batteries
90 Days — Parts
*
Accessory (Kits)
*
Canvas Covers
*
Induction Heating Coils and Blankets
*
MIG Guns
*
Remote Controls
*
Replacement Parts (No Labor)
*
Spoolmate Spoolguns
*
Cables and Non-Electronic Controls
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, switches, slip
rings, relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
5 Years Parts — 3 Years Labor
*
2.
6.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at ITW Welding Products
Group Europe or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
milan_warr 2013−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
Country
Zip/Postal Code
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Italy S.r.l.
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
 2013 Miller Electric Mfg. Co. 2013−01
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it
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