Miller | KJ239046 | Owner Manual | Miller MARK VI User manual

Miller MARK VI User manual
OM-2211
182 413J
October 1998
Processes
Shielded Metal Arc
(Stick) Welding
DC-Gas Tungsten Arc
(DC-TIG) Welding
Flux Cored Arc Welding and
Gas Metal Arc Welding (MIG)
Spray Transfer with VoltageSensing Feeder
Air Plasma Cutting
and Gouging with Spectrum
Plus
Air Carbon Arc Cutting and
Gouging
Description
Multiple Operator Arc Welding Power
Source
Mark VI
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
you may need to fix the problem. Warranty and
to the ISO 9001 Quality
service information for your particular model
System Standard.
are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
Working as hard as you
do − every power source
from Miller is backed by
the most hassle-free warranty in the business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
TABLE OF CONTENTS
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
MIG = GMAW
OM-2211J
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 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. Standard Module Weld Output Connections For CC SMAW And GTAW Welding
Processes Without A Common Work Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Standard Module Weld Output Connections For CC Smaw And GTAW Welding
Processes With A Common Work Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. Parallel Module Weld Output Connections For CC SMAW Welding Process Without
A Common Work Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14. Parallel Module Weld Output Connections For CC SMAW Welding Process With A
Common Work Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15. CC/CV Module Weld Output Connections For CV FCAW Welding Process Without
A Common Work Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16. CC/CV Module Weld Output Connections For CV FCAW Welding Process With
A Common Work Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-17. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-18. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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3
3
4
5
5
5
7
8
8
9
9
10
15
16
17
18
19
20
21
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25
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
1-1. Symbol Usage
Means Warning! Watch Out! There are possible
hazards with this procedure! The possible hazards are
shown in the adjoining symbols.
YMarks 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
YThe 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 NO TAG. Read
and follow all Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable − do not use work clamp or work cable.
YOnly qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
YDuring 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 Keep all panels and covers securely in place.
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.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Use AC output ONLY if required for the welding process.
D Keep your head out of the fumes. Do not breathe the fumes.
D If AC output is required, use remote output control if present on
unit.
D If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
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 If ventilation is poor, use an approved air-supplied respirator.
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding
conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D 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 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 if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-2211 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.
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.
D Wear protective clothing made from durable, flame-resistant
material (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
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 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.
D Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
CYLINDERS can explode if damaged.
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).
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 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 Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Never drape a welding torch over a gas cylinder.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D Never weld on a pressurized cylinder − explosion will result.
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-2211 Page 2
D Never allow a welding electrode to touch any cylinder.
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.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Do not overload building wiring − be sure power supply system
is properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
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.
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.
H.F. RADIATION can cause interference.
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.
D The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D 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.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
ARC WELDING can cause interference.
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.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive electronic equipment.
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 Be sure this welding machine is installed and grounded
according to this manual.
D 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-2211 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
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.
2. Arrange cables to one side and away from the operator.
To reduce magnetic fields in the workplace, use the following
procedures:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-2211 Page 4
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:
SECTION 1 − CONSIGNES DE SECURITE
− LIRE AVANT UTILISATION
som _nd_Fre 4/97
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.
YIdentifie 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
YLes 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 1-5. Veuillez lire et respecter toutes ces
normes de sécurité.
YL’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
YAu 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 Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
D Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
D 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 − ne pas utiliser le connecteur de pièce ou le câble de
retour.
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-2211 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-2211 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
D Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
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 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.
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.
D
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
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 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-2211 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 :
L’extrait suivant est tiré des conclusions générales du document intitulé Biological Effects of Power Frequency Electric & Magnetic Fields −
Background Paper, OTA−BP−E−53 (Washington DC : U.S. Government Printing Office, mai 1989), publié par le Office of Technology
Assessment du Congrès américain : «... il existe maintenant d’abondantes données scientifiques compilées à la suite d’expériences sur
la cellule ou d’études sur des animaux et des humains, qui montrent
clairement que les champs électromagnétiques basse fréquence peuvent avoir des effets sur l’organisme et même y produire des
transformations. Même s’il s’agit de travaux de très grande qualité, les
résultats sont complexes. Cette démarche scientifique ne nous permet pas d’établir un tableau d’ensemble cohérent. Pire encore, elle ne
nous permet pas de tirer des conclusions finales concernant les risques éventuels, ni d’offrir des conseils sur les mesures à prendre pour
réduire sinon éliminer les risques éventuels». (Traduction libre)
1
OM-2211 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
vous.
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 consignes mentionnées précédemment font partie de celles destinées aux personnes ayant recours à un stimulateur cardiaque.
Veuillez consulter votre médecin pour obtenir plus de détails.
SECTION 2 − INSTALLATION
.
A six module unit is illustrated throughout this Owner’s manual. Four module units are available. Installation and operation is similar to that of
a six module unit.
2-1. Specifications
Rated Output At 44 Volts DC
Each Module
Six Or Four
Module Units
250 A At 60% Duty
Cycle
Main Transformer
1500 A At 25% Duty
Cycle
750 A At 100% Duty
Cycle
DC Amperage/Voltage
Range
Max. Open
Circuit Voltage
20 − 315 A In CC Mode
10 − 30 V In CV Mode
With CC/CV Module
75 VDC In CC
Mode
38 VDC In CV
Mode With CC/CV
Module
Amps Input At Rated Output of 750 A,
50 Or 60 Hz, Three-Phase
230 V
380
400
415
440
460 V
575 V
KVA
KW
164
12.5*
97
7.5*
92
7*
91
7*
84
6.5*
82.5
6.2*
66.1
5*
65.2
5*
41.9
3.2*
* While idling
2-2. Volt-Ampere Curves
CC Mode
The volt-ampere curves show the
normal minimum and maximum
voltage and amperage output capabilities of the welding power
source. Curves of other settings
fall between the curves shown.
CV Mode With
CC/CV Module
SB-184 158 / SB-190 886
OM-2211 Page 9
2-3. 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
voltage, or duty cycle before
welding.
YExceeding duty cycle can
damage unit and void
warranty.
The main transformer of the polyweld system has dual duty cycle
ratings, each for a specific amperage output range. If the unit is operated in the 750 ampere range, the
unit is rated at 100% duty cycle.
This means the polyweld system
can be operated at 750 amperes
continuously. When the unit is operated in the 1500 ampere range,
it is rated at 25% duty cycle.
Main Transformer − 100% Duty Cycle at 750 Amperes
Continuous Welding
The sum of the outputs of each
module should not exceed the
rated duty cycle of the main transformer. For example, the polyweld
system can be safely operated at a
load of 1000 amperes at 80 percent duty cycle. This value could
be obtained by operating four modules at a load of 250 amperes at 80
percent duty cycle, or by operating
six modules at a load of 167
amperes at 80 percent duty cycle.
Main Transformer − 25% Duty Cycle at 1500 Amperes
2-1/2 Minutes Welding
7-1/2 Minutes Resting
Single Module − 60% Duty Cycle at 250 Amperes
6 Minutes Welding
4 Minutes Resting
Overheating
A or V
0
15
Minutes
OM-2211 Page 10
OR
Reduce Duty Cycle
duty1 4/95 − SB-184 107-B
2-4. Selecting A Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
3
Movement
Rating Label
Use rating label to determine input
power needs.
4
1
YHigh center of gravity − always
securely tie down unit with adequate chains or other proper restraints when moving to prevent tipping. Do not place unit
where it could tip.
OR
Line Disconnect Device
Locate unit near correct input power supply.
2
Location
4
.
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
IMPORTANT!
36 in
(920mm)
Air Out
36 in
(920mm)
Air In
This unit contains fan blades
with different airflow directions
to provide proper cooling of
components. Consult Owner’s
Manual for correct Part No.
and location.
S-183 992
3
Do not block airflow
to sides of unit.
loc_1 3/96 Ref. ST-801 627-A
OM-2211 Page 11
2-5. Dimensions And Weights
Dimensions
Height*
65 in (1651 mm)
Width
56-3/4 in (1442 mm)
Depth
34-1/4 in (870 mm)
*72 in (1829 mm) with lifting eye
Weight
Each Module
Four Unit Module
Six Module Unit
125 lb (57 kg)
1575 lb (718 kg)
60 Hz − 1825 lb (828 kg)
50 Hz − 1870 lb (848 kg)
2-6. 115 Volts AC GFCI Receptacles And Circuit Breakers
1
115 V 15 A AC GFCI
Receptacles RC9 And RC10
These receptacles supply up to 15
amperes of 115 volts ac power. In
50 Hz models, RC9 is 220 volts, 15
amps AC.
If a ground fault is detected, the
GFCI Reset button pops out and
the circuit opens to disconnect the
faulty equipment. Check for damaged tools, cords, plugs, etc. connected to the receptacle. Press
button to reset receptacle and
resume operation.
.
At least once a month, test button to verify GFCI is working
properly.
2
Circuit Breaker CB1
CB1 protects RC9 from overload. If
CB1 opens, no output is available
from RC9.
1
3
Circuit Breaker CB2
CB2 protects RC10 from overload.
If CB2 opens, no output is available
from RC10.
4
Circuit Breaker CB3
CB3 protects the 115 volts ac
portion of Remote 14 receptacle
RC8 from overload.
2
3
4 5
5
CB4
CB4 protects the 24 volts ac
portion of Remote 14 receptacle
RC8 from overload.
Press button to reset breaker.
Ref. ST-801 627-A
OM-2211 Page 12
2-7. Weld Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 − 60%
Duty Cycle
60 − 100% Duty
Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
700
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
800
4/0
2-2/0
2-3/0
2-4/0
3-4/0
3-4/0
4-4/0
4-4/0
900
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
1000
2-2/0
2-3/0
2-4/0
3-3/0
4-3/0
4-4/0
1250
2-3/0
2-4/0
3-3/0
4-3/0
4-4/0
1500
2-4/0
3-3/0
3-4/0
4-4/0
1750
750
1000
2-750
2-1000
10 − 100% Duty Cycle
2-1000
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.
2-8. Common Work Cable Sizes
Common Work Cable Sizes At Main Transformer
Rated Welding Current
Cable Length
Cable Size
50 ft (15 m)
2 No. 3/0
100 ft (30.5 m)
2 No. 4/0
150 ft (46 m)
3 No. 3/0
200 ft (61 m)
3 No. 4/0
OM-2211 Page 13
2-9. Safety Information For Connecting To Weld Output Terminals
YELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections.
Turn Off welding power source before making any weld output connections.
Do not connect welding output of different polarities to the same structure.
See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
When using Common Work terminal, all connections to the Common Work terminal must be of the same polarity. Also, when welding on the same
work piece, all connections to the work piece must be of the same polarity.
Remove jumper link from any module where work and electrode connections are made directly to the Positive and Negative output terminals.
Do not handle or come in contact with two live electrodes at the same time.
Connect all paralleled modules for the same polarity.
ELECTRIC SHOCK can kill; TWO TIMES NORMAL OPEN-CIRCUIT VOLTS exist between electrode holders of opposite polarity.
Do not touch electrode holders of opposite polarity at the same time.
Separate electrode holders of opposite polarity to prevent contact.
Consult ANSI Z49.1 for common grounding safe practices.
2-10. Weld Output Terminals
YRead and understand safety
information in Section 2-9
before proceeding.
1
2
CC Module
3
4
5
2
1
6
Positive (+) Weld Output
Terminal
Negative (−) Weld Output
Terminal
Positive (+) High Inductance
Weld Output Terminal For CC
SMAW And GTAW Welding
Processes
Positive (+) Low Inductance
Weld Output Terminal For
The CV FCAW Welding
Process
Negative (−) Weld Output
Terminal
Weld Output Terminal Cover
(Typical For All Weld Output
Terminals)
Cover all weld output terminals
with weld output terminal covers.
6
Go to Section 2-11 and/or 2-12 for
standard module weld output connections, or Section 2-13 and/or
2-14 for parallel module weld
output connections. Go to Section
2-15 and/or 2-16 for CV FCAW
weld output connections.
CC/CV Module
3
OM-2211 Page 14
4
5
Ref. ST-801 627-A
2-11. Standard Module Weld Output Connections For CC SMAW And GTAW Welding
Processes Without A Common Work Terminal
YRead and understand safety
information in Section 2-9
before proceeding.
See Section 2-7 for proper cable
size.
3
1
2
Electrode Holder Cable
Work Cable
For Electrode Positive (Reverse
Polarity/DCEP), connect work
cable to Negative (−) terminal and
electrode holder cable to Positive
(+) terminal (see Section 2-10).
For Electrode Negative (Straight
Polarity/DCEN), reverse cable
connections.
3
Weld Output Terminal Cover
(Typical For All Weld Output
Terminals)
Cover all weld output terminals
with weld output terminal covers.
4
4
Cable Restraint
Route cables through restraints as
shown.
NOTE:When using a CC/CV module (not shown) for CC operation,
use Positive (+) High Inductance
weld output terminal (see Section
2-10). Process Selector switch
(see Section 3-2) must be in
SMAW Hot Start On, or SMAW Hot
Start Off position.
1
2
Tools Needed:
3/4, 7/8 in
Ref. ST-801 641-A
OM-2211 Page 15
2-12. Standard Module Weld Output Connections For CC Smaw And GTAW Welding
Processes With A Common Work Terminal
YRead and understand safety
information in Section 2-9
before proceeding.
YINADEQUATE WORK CABLE CONNECTIONS can cause
serious damage to input power service and create a
hazardous condition.
Connect a weld cable of adequate size between the Common Work Connection and the workpiece whenever any
module(s) is connected to use the Common Work terminal.
See Section 2-7 for proper cable
size.
1
2
3
4
Electrode Holder Cable
Work Jumper Cable
Common Work Terminal
Common Work Cable
For Electrode Positive (Reverse
Polarity/DCEP), connect work
jumper cables from Negative (−)
terminals to Common Work terminal, and connect electrode holder
cables to Positive (+) terminals
(see Section 2-10).
When using Common Work terminal, all connections to the
Common Work terminal must be of the same polarity.
Do not exceed duty cycle of machine.
6
For Electrode Negative (Straight
Polarity/DCEN), connect work
jumper cables from Positive (+) terminals to Common Work terminal,
and connect electrode holder
cables to Negative (−) terminals
(see Section 2-10).
Connect as many modules as required. Do not exceed duty cycle of
machine.
5
Cable Restraint
Route cables through restraints as
shown.
6
Weld Output Terminal Cover
(Typical For All Weld Output
Terminals)
Cover all weld output terminals
with weld output terminal covers.
NOTE:When using a CC/CV module (not shown) for CC operation,
use Positive (+) High Inductance
weld output terminal (see Section
2-10). Process Selector switch
(see Section 3-2) must be in
SMAW Hot Start On, or SMAW Hot
Start Off position.
5
3
2
1
4
Tools Needed:
.
For common work connection, work cable must be able to carry combined weld
3/4, 7/8 in
output of all modules using the Common Work Terminal (see Section 2-8 for proper cable size). The Common Work Terminal is isolated from the unit frame.
Ref. ST-801 641-A
OM-2211 Page 16
2-13. Parallel Module Weld Output Connections For CC SMAW Welding Process Without
A Common Work Terminal
YRead and understand safety
information in Section 2-9
before proceeding.
See Section 2-7 for proper cable
size.
YUNDERSIZED WELD CABLES can cause fire.
1
2
3
Use single cable of adequate capacity to carry the total combined amperage of the paralleled modules.
Securely cover common connections with proper insulating material.
Do not exceed duty cycle of machine.
.
Single work cable or electrode holder cable must be able to carry combined weld
output of all modules connected in parallel (see Section 2-7).
Set Amperage/Voltage Adjustment controls on all paralleled modules for the same
output.
Electrode Holder Cable
Work Cable
Connection Point
For Electrode Positive (Reverse
Polarity/DCEP), connect separate
cables of same size and length
from Positive (+) terminals (see
Section 2-10) to a suitable connection point connecting to a single
electrode cable. Connect separate
cables of same size and length
from Negative (−) terminals to a
suitable connection point connecting to a single work cable.
For Electrode Negative (Straight
Polarity/DCEN), reverse cable
connections.
Connect as many modules as required. Do not exceed duty cycle of
machine.
5
4
Cable Restraint
Route cables through restraints as
shown.
5
Weld Output Terminal Cover
(Typical For All Weld Output
Terminals)
Cover all weld output terminals
with weld output terminal covers.
NOTE:When using a CC/CV module (not shown) for CC operation,
use Positive (+) High Inductance
weld output terminal (see Section
2-10). Process Selector switch
(see Section 3-2) must be in
SMAW Hot Start On, or SMAW Hot
Start Off position.
4
1
3
2
Tools Needed:
YSecurely cover
connection with
proper insulating material.
3/4, 7/8 in
Ref. ST-801 641-A
OM-2211 Page 17
2-14. Parallel Module Weld Output Connections For CC SMAW Welding Process
With A Common Work Terminal
YRead and understand safety
information in Section 2-9
before proceeding.
See Section 2-7 for proper size
cable.
YUNDERSIZED WELD CABLES can cause fire.
Use single cable of adequate capacity to carry the total combined amperage of the paralleled modules.
1
2
3
4
5
Securely cover common connections with proper insulating material.
Do not exceed duty cycle of machine.
.
Single work cable or electrode holder cable must be able to carry combined weld
output of all modules connected in parallel (see Section 2-7).
Electrode Holder Cable
Connection Point
Work Jumper Cable
Common Work Cable
Common Work Terminal
For Electrode Positive (Reverse
Polarity/DCEP), connect work
jumper cable across Negative (−)
terminal and Common Work terminal for each paralleled module.
Connect separate cables of same
size and length from Positive (+)
terminals (see Section 2-10) to a
suitable connection point connecting to a single electrode holder
cable.
Set Amperage/Voltage Adjustment controls on all paralleled modules for the same
output.
When using Common Work terminal, all connections to the Common Work terminal
must be of the same polarity.
7
For Electrode Negative (Straight
Polarity/DCEN), connect work
jumper cable across Positive (+)
terminal (see Section 2-10) and
Common Work terminal for each
paralleled module. Connect separate cables of same size and length
from Negative (−) terminals to a
suitable connection point connecting to a single electrode holder
cable.
Connect as many modules as required. Do not exceed duty cycle of
machine.
6
6
Cable Restraint
Route cables through restraints as
shown.
5
7
Weld Output Terminal Cover
(Typical For All Weld Output
Terminals)
Cover all weld output terminals
with weld output terminal covers.
3
NOTE:When using a CC/CV module (not shown) for CC operation,
use Positive (+) High Inductance
weld output terminal (see Section
2-10). Process Selector switch
(see Section 3-2) must be in
SMAW Hot Start On, or SMAW Hot
Start Off position.
4
1
Tools Needed:
2
3/4, 7/8 in
.
For common work connection, work cable must be able to carry combined weld output
of all modules using the Common Work Terminal (see Section 2-8 for proper cable size).
The Common Work Connection panel is isolated from the unit frame.
YSecurely cover connection with proper
insulating material.
Ref. ST-801 641-A
OM-2211 Page 18
2-15. CC/CV Module Weld Output Connections For CV FCAW Welding Process Without
A Common Work Terminal
YRead and understand safety
information in Section 2-9
before proceeding.
See Section 2-7 for proper cable
size.
1
3
2
Wire Feeder Connection
Cable
Work Cable
For Flux Cored Arc Welding
(FCAW), Electrode Negative
(DCEN/Straight Polarity) is typically used. Connect work cable to
Positive (+) Low Inductance terminal. Connect wirefeeder connection cable to Negative (−) weld terminal and wire feeder. (see Section
2-10).
For Electrode Positive (Reverse
Polarity/DCEP), reverse cable
connections.
4
3
Weld Output Terminal Cover
(Typical For All Weld Output
Terminals)
Cover all weld output terminals
with weld output terminal covers.
4
Cable Restraint
Route cables through restraints as
shown.
2
2
1
1
Wire Feeder
Wire Feeder
Tools Needed:
3/4, 7/8 in
Ref. ST-802 199
OM-2211 Page 19
2-16. CC/CV Module Weld Output Connections For CV FCAW Welding Process With A
Common Work Terminal
YRead and understand safety
information in Section 2-9
before proceeding.
See Section 2-7 for proper cable
size.
YINADEQUATE WORK CABLE CONNECTIONS can cause
serious damage to input power service and create a
hazardous condition.
1
Connect a weld cable of adequate size between the Common Work Connection and the workpiece whenever any
module(s) is connected to use the Common Work terminal.
6
When using Common Work terminal, all connections to the
Common Work terminal must be of the same polarity.
2
3
4
5
Wire Feeder Connection
Cable
Work Jumper Cable
Common Work Terminal
Common Work Cable
Cable Restraint
Route cables through restraints as
shown.
Do not exceed duty cycle of machine.
For Flux Cored Arc Welding
(FCAW), Electrode Negative
(DCEN/Straight Polarity) is typically used. Connect work jumper
cable from Positive (+) Low Inductance terminals to Common Work
terminal. Connect wirefeeder connection cables from Negative (−)
terminals to wire feeders. (see
Section 2-10).
For Electrode Positive (Reverse
Polarity/DCEP), connect work
jumper cables from Negative (−)
terminals to Common Work terminal. Connect wire feeder connection cables from Positive (+) Low
Inductance terminals to wire feeders. (see Section 2-10).
5
6
2
3
Weld Output Terminal Cover
(Typical For All Weld Output
Terminals)
Cover all weld output terminals
with weld output terminal covers.
2
1
1
4
Wire Feeder
Wire Feeder
Tools Needed:
3/4, 7/8 in
Ref. ST-802 199
OM-2211 Page 20
2-17. Remote 14 Receptacle Information
Socket*
Ref. ST-801 627-A
A
B
K
J
I
H
C L N
M
D
G
E F
Socket Information
24 VOLTS AC
A
24 volts ac. Protected by circuit breaker CB4.
24 VOLTS AC
B
Contact closure to A completes 24 volts ac
contactor control circuit.
REMOTE
OUTPUT
CONTROL
C
Output to remote control; +10 volts dc in CV, 0 to
+10 volts dc in CC.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
A/V
F
AMPERAGE
VOLTAGE
Current feedback; 0 to +10 volts dc, 1 volt per
100 amperes.
H
Voltage feedback; +1 volts dc per 10 arc volts.
115 VOLTS AC
I
115 volts, 15 amperes, 60 Hz ac. Protected by
circuit breaker CB3.
115 VOLTS AC
J
Contact closure to I completes 115 volts ac
contactor control circuit.
GND
K
Chassis common.
GND
G
Circuit common for 24 and 115 volts ac circuits.
REMOTE
OUTPUT
CONTROL
*The remaining sockets are not used.
2-18. Electrical Service Guide
60 Hz Models
50 Hz Models
Input Voltage
230
460
575
380
400
415
440
Input Amperes At Rated Output
164
82
66
97
92
91
84
Max Recommended Standard Fuse Or Circuit Breaker Rating In
Amperes
250
125
100
150
150
125
125
Min Input Conductor Size In AWG/Kcmil
1/0
4
4
3
3
3
3
Max Recommended Input Conductor Length In Feet (Meters)
163
(50)
346
(106)
541
(165)
280
(85)
310
(94)
310
(94)
375
(114)
4
6
8
6
6
6
6
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).
S-0092J
OM-2211 Page 21
2-19. Placing Jumper Links And Connecting Input Power
Connect
GND/PE
Conductor
First.
L1 (U)
Do not
overtighten
jumper link nuts.
L2 (V)
L3 (W)
3
Input
Contactor
GND/PE
3
230 VOLTS
575 VOLTS
460 VOLTS
L1
L2
220 VOLTS
L3
S-174 973-B
(Factory
Option)
380 VOLTS
YAlways connect
grounding
conductor first.
400 − 415 VOLTS
440 − 460 VOLTS
1
S-168 918
= GND/PE
2
Tools Needed:
1/2 in
3/8 in
Ref. ST-801 627
Have only qualified persons make this installation.
Move jumper links to match input voltage, and label on unit.
Check input voltage available at site.
2
1
See Section 2-18.
Jumper Link Label - Only One Is On Unit
OM-2211 Page 22
Input And Grounding Conductors
3
Line Disconnect Device
See Section 2-18.
Close access door.
SECTION 3 − OPERATION
3-1. CC Module Controls
1
6
2
3
5
4
7
Ref. ST-181 356-B / Ref. ST-189 724-A
1
Arc Force (Dig) Control
Control increases SMAW short-circuit amperage from 0−160 amps which allows the
operator to use a very short arc length without
sticking the electrode.
2
Hot Start Switch
Turn switch Off for GTAW and SMAW normal
operation. Turn switch On for SMAW to pro-
vide additional starting amperage for hard to
start electrodes.
Remote position, and connect remote device
(see Section 2-17).
3
Amperage Adjustment Control
6
4
High Temperature Shutdown Light
5
Remote Amperage Control Switch
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position, and connect remote device
(see Section 2-17).
For front panel control, place switch in Panel
position. For remote control, place switch in
7
Output Switch (Contactor)
Power Switch
OM-2211 Page 23
3-2. CC/CV Module Controls
1
6
2
3
4
5
7
1 Arc Force (Dig) Control
Control increases SMAW short-circuit amperage from 0−160 amps which allows the
operator to use a very short arc length without
sticking the electrode.
2 Process Selector Switch
Place switch in (down) Off position for GTAW
and SMAW normal operation. Place switch in
(center) On position for SMAW to provide
additional starting amperage for hard to start
electrodes. Place switch in up position for
OM-2211 Page 24
GMAW.
3 Amperage/Voltage Adjustment Control
When Process selector switch is in either
SMAW position, turn control clockwise to increase amperage (read amperage from outside scale). When Process selector switch is
in GMAW position, turn control clockwise to
increase voltage (read voltage from inside
scale).
4 High Temperature Shutdown Light
5 Remote Amperage Control Switch
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position, and connect remote device
(see Section 2-17).
6
Output Switch (Contactor)
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position, and connect remote device
(see Section 2-17).
7
Power Switch
SECTION 4 − MAINTENANCE AND TROUBLESHOOTING
4-1. Routine Maintenance
YDisconnect power before maintaining.
.
Maintain more often during severe conditions.
3 Months
Replace
unreadable
labels.
Clean and
tighten
weld terminals.
Repair or
replace
cracked
weld cable
and cords
6 Months
Blow out or vacuum inside.
Or
OM-2211 Page 25
4-2. Overload Protection
YTurn Off unit, and disconnect input power.
Fuse F1
Fuses F1 protects the control
transformer from overload. If F1
opens, weld output and fan motors
stop. To replace fuse, proceed as
shown:
Fuse F1
1
2
Fuse Holder Cover
Fuse (See Parts List)
.
If fuse
continues to open,
contact Factory Authorized
Service Agent.
Fuse Links
3
Fuse Links
A pair of fuse links protects each
module from overload. If a fuse link
opens, low weld output is available
at the applicable module. If both
fuse links open, no weld output is
available at the affected module.
To replace fuse(s), remove appropriate rear panel, check
fuse(s), and replace if needed.
Reinstall panel.
.
If fuse(s)
continues to open,
contact Factory Authorized
Service Agent.
2
1
Turn
Pull Out And Replace Fuse
(Install Flat End Of Fuse Into Cover)
Turn
Tools Needed:
3/8 in
Fuse Links
3
Tools Needed:
1/2 in
OM-2211 Page 26
Ref. ST-801 627
4-3. Troubleshooting
Trouble
No weld output from any module; fan motors off; pilot
light off.
Remedy
Be sure Power switch is On (see Section 3-1).
Place line disconnect device in On position (see Section 2-19).
Check line fuse(s), and replace if necessary, or reset circuit breakers (see Section 2-19).
Check for proper input power connections (see Sections 2-19).
Check for proper jumper link position (see Sections 2-19).
Check fuse F1, and replace if necessary (see Section 4-2).
Have Factory Authorized Service Agent check Power switch and replace if necessary.
No weld output from any module; fan motors on; pilot
light on.
Have Factory Authorized Service Agent check contactor and replace if necessary.
Limited output and low open circuit voltage from all
modules.
Check incoming power for correct voltage. Replace line fuse if open or reset circuit
breaker.
Check for proper jumper link position (see Section 2-19)
No weld output from one module only.
Check module fuse links, and replace if necessary (see Section 4-2).
Low weld output from one module only. No amperage control.
Place Remote Amperage control switch in Off position or connect remote amperage
control to Remote Amperage Control receptacle (see Section 3-1).
Check module fuse links, and replace if necessary (see Section 4-2).
Module thermostat open (overheating). Allow module to cool down; thermostat closes
when module has cooled (see Section 2-3).
Erratic weld output.
Clean and tighten all weld cable connections.
Check for proper size and type of weld cable (see Section 2-7).
Check for proper input power connections (see Sections 2-19).
Use dry, properly stored electrodes.
Erratic weld output (CV mode).
Check wire feeder installation according Owner’s Manual.
Check position of Process Selector switch (see Section 3-2).
Check for proper connections to weld output terminals (see Section 2-15 and/or 2-16).
No weld output at 115 volts ac duplex receptacles.
Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 2-6)
Fan motor(s) does not run when Power switch is On.
Check fuse F1, and replace if necessary (see Section 4-2).
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motors.
For GTAW, wandering arc − poor control of direction
of arc.
Select proper size tungsten.
Properly prepare tungsten.
Tungsten electrode oxidizing and not remaining
bright after conclusion of weld.
Shield weld zone of drafts.
Properly prepare tungsten.
Replace torch parts if water has leaked into torch.
No 115 volts ac output at Remote 14 receptacle.
Reset circuit breaker CB3 (see Section 2-6).
No 24 volts ac output at Remote 14 receptacle.
Reset circuit breaker CB4 (see Section 2-6).
No weld output from any module. All six overtemp
lights on.
Transformer thermostat(s) open (overheating). Allow transformer to cool; thermostat(s)
close when transformer has cooled (see Section 2-3).
OM-2211 Page 27
SECTION 5 − ELECTRICAL DIAGRAM
Figure 5-1. Circuit Diagram
OM-2211 Page 28
SD-190 767-B
OM-2211 Page 29
SECTION 6 − PARTS LIST
.
Hardware is common and
not available unless listed.
8
7
1
6
5
4
3
2
IMPORTANT!
This unit contains fan blades
with different airflow directions
to provide proper cooling of
components. Consult Owner’s
Manual for correct Part No.
and location. . . . . . S-183 992
9
35
10
35
34
33
11
32
31
21
22
28
25
26
30
24
23
12
20
19
18
29
17
13
16
15
12
Figure 6-1. Complete Assembly
OM−2211 Page 30
14
ST-801 629-B / ST-801 771
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
CC CC/CV
Figure 6-1. Complete Assembly
. . . 1 . . . . . . . . . . . . . . . 182 497 . . RECTIFIER, si diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 2 . . . . . . . . . . . . . . . 188 692 . . . . CLAMP, thyristor rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . .
. . . 3 . . . SCR1-6 . . . 161 668 . . . . THYRISTOR, SCR 300A 300V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . .
. . . 4 . . . . C7-12 . . . . 048 420 . . . . CAPACITOR, cer disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . .
. . . 5 . . . . . . . . . . . . . . . 177 316 . . . . HEAT SINK, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . .
. . . 6 . . . . . . . . . . . . . . . 177 317 . . . . HEAT SINK, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . 7 . . . . . . . . . . . . . . . 166 667 . . . . CLAMP, spring thyristor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . .
. . . 8 . . . . . TP1 . . . . . 185 679 . . . . THERMOSTAT, NC open 211F . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . RC16 . . . . 158 720 . . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 9 . . . . . . . . . . . . . . . 182 322 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . 182 329 . . FUSE PANEL, module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . .
. . . . . . . . . . . . . . . . . . . . . 059 945 . . . . FUSE LINKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . 10 . . . . . . . . . . . . . . . 182 318 . . PANEL, side upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . . . . . . . . . . . . . . . . . . . 124 275 . . CHAMBER, plenum 14 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . .
. . . 11 . . . . . . . . . . . . . . . 183 168 . . BLADE, fan 14.00 3wg 28D CW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . . . . . . . . FM1-4 . . . . 116 190 . . MOTOR, 1/2HP 230V 155RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . .
. . . 12 . . . . . . . . . . . . . . . 183 004 . . PANEL, side lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . . . . . . . . . . . . . . . . . . . 182 321 . . PANEL, blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . .
. . . . . . . . . . . . . . . . . . . . . 182 320 . . PANEL, primary access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . 159 244 . . PRIMARY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . 183 658 . . . . NUT, 10-32 brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As Reqd
. . . . . . . . . . . . . . . . . . . . . 038 887 . . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . As Reqd
. . . . . . . . . . . . . . . . . . . . . 177 225 . . JUMPER LINK, kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . 182 396 . . STRIP, mtg term strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . 038 772 . . BLOCK, term 20A 6 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . .
. . . . . . . . . . . . . . . . . . . . . 601 219 . . LINK, jumper term blk 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As Reqd
. . . . . . . . . . . . . . . . . . . . . 159 034 . . HOLDER, fuse mintr 10.3mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . F1 . . . . . . 156 065 . . FUSE, crtg .5A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . 182 706 . . DOOR, primary access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . 168 343 . . HINGE, cont polyolefin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . 13 . . . . . . . . . . . . . . . 182 317 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 14 . . . . . . . . . . . . . . . 134 464 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 15 . . . . . . . . . . . . . . . 189 723 . . PANEL, power/duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 16 . . . . . S2 . . . . . . 159 039 . . SWITCH, SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 17 . . CB3,4,1,2 . . 093 995 . . CIRCUIT BREAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . .
. . . . . . . . . . . . . . . . . . . . . 026 758 . . BOOT, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . .
. . . 18 . . . . . . . . . . . . . . . 154 022 . . COVER, receptacle duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . . . . . . . RC9,10 . . . . 147 939 . . RECEPTACLE, str dx grd 2P3W 15A (60 Hz) . . . . . . . . . . . . . . . . . 2 . . . .
. . . . . . . . . . . RC9 . . . . . 604 130 . . RECEPTACLE, str dx grd 2P3W 15A 250V (50 Hz) . . . . . . . . . . . . 2 . . . .
. . . 19 . . . . . . . . . . . . . . . 182 496 . . TERMINAL ASSEMBLY, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . 601 840 . . . . NUT, 500-13 .88hex .32H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . .
. . . . . . . . . . . . . . . . . . . . . 601 839 . . . . NUT, 500-13 .75hex 44H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
. . . . . . . . . . . T1 . . . . . . 192 745 . . TRANSFORMER, pwr main 230/460/575 (60Hz) . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . T1 . . . . . . 190 129 . . TRANSFORMER, pwr main 380/400 - 415/440 - 460 (50Hz) . . . . 1 . . . .
. . . . . . . . . . . T2 . . . . . . 159 042 . . TRANSFORMER, control (60Hz models) . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . T2 . . . . . . 159 043 . . TRANSFORMER, control (50Hz models) . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . TP2, 3 . . . . 163 266 . . THERMOSTAT, NC, open 150c (included w/T1) . . . . . . . . . . . . . . . 2 . . . .
. . . . . . . . . . TP4, 5 . . . . 168 891 . . THERMOSTAT, NC, open 80c (included w/T1) . . . . . . . . . . . . . . . . 2 . . . .
. . . . . . . . . . . . W . . . . . . 183 808 . . CONTACTOR, DEF PRP 90A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . C21-23 . . . . 163 906 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . .
. . . . . . . . . . . . . . . . . . . . . 183 167 . . CONNECTOR, clamp cable 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, lower Mark VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . . 168 384 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . PLG7 . . . . 152 249 . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . RC1 . . . . . 168 845 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . RC7 . . . . . 168 846 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . . . . . . . . . RC3 . . . . . 169 240 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
. . . 21 . . . . . R3 . . . . . . 097 459 . . RESISTOR, WW fxd 375W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
1
3
6
6
3
2
3
1
1
1
6
2
2 .
4
2
4
2
9
1
1
1
1
8
1
1
1
2
1
1
1
1
4
4
2
2
2
1
4
2
1
1
1
1
2
2
1
3
1
1
1
1
1
1
1
1
OM-2211 Page 31
Item
No.
Dia.
Mkgs.
Part
No.
Quantity
Description
CC
CC/CV
Figure 6-1. Complete Assembly
. . . 22 . . . . . Z1 . . . . . . 165 612 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . Z1 . . . . . . 163 222 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 182 326 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 190 915 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 181 246 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 26 . . . . . . . . . . . . . . . 180 732 . . BOOT, negative output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 28 . . . . . . . . . . . . . . . 181 245 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 2
. . . . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 3
. . . . . . . . . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 3
. . . 29 . . . . . . . . . . . . . . . 191 143 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 30 . . . . . . . . . . . . . . . 181 356 . . NAMEPLATE (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 190 033 . . NAMEPLATE (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 182 454 . . NAMEPLATE, cc/cv (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . 191 566 . . NAMEPLATE, cc/cv (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . PL1 . . . . . 159 522 . . LED, yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . R1,2 . . . . . 035 897 . . POTENTIOMETER, slot 1T 2W 1K ohm . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . . . . . . . . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . . 097 922 . . KNOB, pointer .875dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . . . . . . . . . . . 170 391 . . CONNECTOR, circ MS protective . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . S1,3,4 . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 2
. . . . . . . . . . . S1 . . . . . . 011 610 . . SWITCH, tgl SPDT 15A 125VAC on-off-on . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 179 848 . . BOOT, positive output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 2
. . . 32 . . . . . PC1 . . . . . 188 318 . . CIRCUIT CARD ASSEMBLY, control (60Hz models) . . . . . . . . . . . 1
. . . 32 . . . . . PC1 . . . . . 190 136 . . CIRCUIT CARD ASSEMBLY, control (50Hz models) . . . . . . . . . . . 1
. . . 32 . . . . . PC1 . . . . . 187 982 . . CIRCUIT CARD ASSEMBLY, control (60Hz models) . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . PC1 . . . . . 191 293 . . CIRCUIT CARD ASSEMBLY, control (50Hz models) . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . 159 863 . . ELECTRONICS BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 34 . . . . . HD1 . . . . . 168 829 . . TRANSDUCER, current 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . C2, 4, 5 . . . 128 750 . . CAPACITOR, cer disc (C4 used on cc/cv module only) . . . . . . . . . 2 . . . . 3
. . . . . . . . . . . . . . . . . . . . . 176 167 . . NUT, 250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . RC8/C3,6,14,15 182 360 . . RECEPTACLE/CAPACITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . PLG14 . . . . 182 363 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . . RC5 . . . . . 152 249 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . PLG6 . . . . 168 847 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . . . . . . . PLG16 . . . . 169 242 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 35 . . . . . . . . . . . . . . . 180 165 . . BLADE, fan 14.00 3wg 28D CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM−2211 Page 32
Effective January 1, 1998
(Equipment with a serial number preface of “KJ” 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, 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.
2.
5 Years Parts − 3 Years Labor
*
Original main power rectifiers
*
Inverters (input and output rectifiers only)
3 Years — Parts and Labor
*
3.
Transformer/Rectifier Power Sources
*
Plasma Arc Cutting Power Sources
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power Supplies
*
Intellitig
*
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor
*
Motor Driven Guns (w/exception of Spoolmate 185)
*
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
*
Robots
*
IHPS Power Sources
*
Water Coolant Systems
*
HF Units
*
Grids
*
Spot Welders
*
Load Banks
*
SDX Transformers
*
Miller Cyclomatic Equipment
*
Running Gear/Trailers
*
Plasma Cutting Torches (except APT, ZIPCUT &
PLAZCUT Models)
*
Deutz Engines (outside North America)
*
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 and Labor
*
MIG Guns/TIG Torches
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate 185
Miller’s True Blue Limited Warranty shall not apply to:
1.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
2.
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customer’s risk and expense. Miller’s option of
repair or replacement will be F.O.B., Factory at Appleton,
Wisconsin, or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
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 1/98
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
To locate distributor nearest you call
1-800-4-A-Miller.
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & 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
 1998 Miller Electric Mfg. Co.
9/98
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