Miller | LC436238 | Owner Manual | Miller MARK VIII-2 User manual

Miller MARK VIII-2 User manual
OM-218
029 920U
September 2002
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
With Optional Equipment:
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Plasma Cutting
and Gouging
Description
Arc Welding Power Source
MARK VIII-2
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
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.
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 orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
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 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Selecting A Location And Moving Polyweld System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights And Base Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Selecting And Preparing Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Weld Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Remote Amperage Control Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Remote Contactor Control Connections (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Amperage Adjustment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Power Switch Push Buttons And Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Blank Module Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – SELECTING AND PREPARING TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . .
7-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding . . . . . . . . . . . . . . . .
7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Positioining The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-218 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-218 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-218 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-218 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Y Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de
sécurité.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique, et décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.
D Ne jamais toucher les pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.
D
D
D
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
D Installer et mettre à la terre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D
D
D
D
D
D
D Eloigner votre tête des fumées. Ne pas respirer
les fumées.
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un
surveillant dûment formé de se tenir à proximité. Des fumées et des
gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
rayons de l’arc peuvent réagir en présence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien
ventilé, et si nécessaire, en portant un respirateur à alimentation
d’air. Les revêtements et tous les métaux renfermant ces éléments
peuvent dégager des fumées toxiques en cas de soudage.
OM-218 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-218 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
D
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.
D Ne pas toucher des parties chaudes à mains nues
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de
se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec une
bouteille.
D Ne jamais souder une bouteille pressurisée – risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables.
D Rester à l’écart des organes mobiles comme le
ventilateur.
D Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables
D Ne pas surcharger l’installation électrique – s”assurer que l’alimentation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un engin d’une capacité appropriée pour
soulever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
D
D
D Prévoir une période de refroidissement, respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
D Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil
de soudage.
D Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de radio–navigation et de communication, les services
de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.
D
D
D
D
D
D L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-218 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-218 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – SPECIFICATIONS
2-1. Specifications
Rated Welding
Output For Main
Transformer
Rated Welding
Output For Each
Module
800 A @ 40 Volts DC,
100% Duty Cycle;
1600 A @ 40 Volts DC,
25% Duty Cycle
200 A @ 40 Volts DC,
60% Duty Cycle
Amperes Input at Rated Load Output, 60
Hz, Three-Phase
Max OCV DC
230 V
460 V
575 V
KVA
KW
80
170
8*
85
4*
68
3.2*
68
3.18*
48.6
2.65*
*While idling
2-2. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
each module. Curves of other settings fall between the curves
shown.
ssb1.1* 10/91 – SB-083 110-C
OM-218 Page 9
2-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
For Each Module And Total System
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.
Y Exceeding duty cycle can
damage unit and void
warranty.
60% Duty Cycle At 200 Amperes
6 Minutes Welding
4 Minutes Resting
For Main Transformer
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 800 ampere range,
the unit is rated at 100% duty cycle. This means the polyweld system can be operated at 800 amperes continuously. When the unit is operated in the 1600 ampere
range, it is rated at 25% duty cycle.
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 60 percent duty cycle. This value could be obtained by
operating five modules at a load of 200 amperes at 60 percent duty cycle, or by
operating eight modules at a load of 125 amperes at 60 percent duty cycle.
Overheating
Thermostat TP1 protects the polyweld system. If main transformer T1 gets too hot,
TP1 opens and weld output stops. The stabilizer in each of the eight modules is protected from overheating by thermostat TPX1 (“X” represents the number of the
applicable module, 1–8). If overheating of a stabilizer occurs, the associated thermostat opens, reducing weld output to a minimum that cannot be regulated. The
fans keep running to cool the stabilizer. Wait several minutes before trying to weld.
0
15
minutes
When overheated, thermostat
opens, output decreases or stops,
and cooling fans keep running.
Let fans run for
15 minutes.
Start welding.
ssb10.1* 1/94 – SB-002 919-C / ST-144 567-A
OM-218 Page 10
SECTION 3 – INSTALLATION
3-1. Selecting A Location And Moving Polyweld System
1
Lifting Eye
2
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Y Disconnect input power conductors
from deenergized supply BEFORE
moving polyweld system.
If using lifting forks, extend forks
beyond opposite side of unit.
3
Movement
Rating Label
Use rating label to determine input
power needs.
1
4
Line Disconnect Device
Locate unit near correct input power supply.
OR
2
Location And Airflow
18 in
(460 mm)
4
18 in
(460 mm)
18 in
(460 mm)
Special installation may be required
where gasoline or volatile liquids are
present – see NEC Article 511 or
CEC Section 20.
18 in
(460 mm)
3
18 in
(460 mm)
Do not block airflow
to bottom of unit.
ssb9.1 5/94 – ST-801 180 / ST-144 567-A
OM-218 Page 11
3-2. Dimensions, Weights And Base Mounting Hole Layout
NOTE
Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.
Dimensions
H
A
B
C
Front
D
G
J
A
77-1/4 in (1943 mm)
B
72 in (1829 mm)
C
40 in (1016 mm)
D
52-1/2 in (1334 mm)
E
3/4 in (19 mm)
F
38-1/2 in (978 mm)
G
26-1/4 in (667 mm)
H
36 in (914 mm)
J
1/2 in Dia. (13 mm Dia.)
4 Holes
Weight
E
F
Ref. ST-144 567-A
4050 lb (1837 kg)
3-3. Selecting And Preparing Weld Output Cables
1
Weld Output Cable
Determine total cable length in weld
circuit and maximum welding amperes. Use Section 3-4 to select
proper cable size.
Use shortest cables possible.
Do not use damaged cables.
2
Terminal Lug
Use lugs of proper amperage
capacity and hole size for connecting to work clamp, electrode holder,
and weld output terminals.
3
Insulated Electrode Holder
Install according to manufacturer’s
instructions.
4
Work Clamp
Install onto work cable.
2
2
3
1
10 ft (3 m)
4
For Example,
Total Cable
Length In Weld
Circuit = 20 ft (6 m)
Tools Needed:
10 ft (3 m)
sb6.1* 5/94 – Ref. ST-144 570-A / Ref. S-0653
OM-218 Page 12
3-4. Weld Cable Size
Total Cable (Copper) Length In Weld Circuit Not Exceeding*
50 ft Or Less
(15m)
100 ft
(30m)
150 ft
(45 m)
Welding
Amperes
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 Thru 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
2
2
1
1/0
2/0
3/0
4/0
4/0
250
1
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
2/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
2/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
4/0
4/0
4/0
2-2/0
2-3/0
2-4/0
1000
1000
600
4/0
4/0
2-2/0
2-3/0
2-4/0
1000
1000
2-750
700
4/0
2-2/0
2-3/0
2-4/0
1000
1000
2-750
2-750
800
2-2/0
2-2/0
2-3/0
2-4/0
1000
2-750
2-750
2-1000
900
2-3/0
2-3/0
2-4/0
1000
1000
2-750
2-1000
2-1000
1000
2-3/0
2-3/0
2-4/0
1000
2-7500
2-750
2-1000
2-1000
1250
2-4/0
2-4/0
750
2-750
2-750
2-1000
2-1000
1500
500
750
1000
2-750
2-1000
2-1000
1750
750
1000
2-750
2-1000
2-1000
2000
750
1000
2-750
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.
S-0008-C
3-5. Connecting To Weld Output Terminals
WARNING
ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical connections.
•
•
•
•
•
•
•
•
Do not touch live electrical parts.
Turn Off polyweld system by pressing Power Off push button 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 Positive or Negative weld output terminal is jumper linked to the Frame Connection terminal and the work cable is connected to the Common Work Connection stud on the machine base, do not connect a cable between the remaining weld output
terminal and the work.
Remove jumper link from any module where work and electrode connections are made directly to the Positive and Negative
output studs.
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.
OM-218 Page 13
A. Standard Module Connections
Y READ SAFETY BLOCKS at start of Section 3-5 before proceeding.
INADEQUATE WORK CABLE CONNECTIONS can cause serious
damage to input power service and create a hazardous condition.
Connect an electrical cable of adequate size between the common
work connection terminal and the workpiece whenever any module(s) is connected to use the frame connection terminal and the
common work connection terminal.
Cable Restraint
Route all cables under cable
restraint.
Separate Work Connections
See Section 3-4 for proper cable
size.
2
Negative (–) Weld Output
Terminal
3
Work Cable
4
Positive (+) Weld Output
Terminal
5
Electrode Holder Cable
3
For Electrode Positive (Reverse
Polarity/DCEP), connect work
cable to Negative (–) terminal and
electrode holder cable to Positive
(+) terminal.
5
For Electrode Negative (Straight
Polarity/DCEN), reverse cable
connections.
1
Common Work Connections
4
2
Separate Work
Connections
1
8
9
Common Work
Connections
6
Common Work Connection
Terminal
7
Common Work Cable
See Table 3-1 for proper cable size.
8
Frame Connection Terminal
9
Jumper Link
For Electrode Negative (Straight
Polarity/DCEN), connect jumper
link across Positive (+) terminal and
Frame Connection terminal, and
connect electrode holder to Negative (–) terminal.
6
7
For Electrode Positive (Reverse
Polarity/DCEP), connect jumper
link across Negative (–) terminal
and Frame Connection terminal,
and connect electrode holder to
Positive (+) terminal.
For common work connection, work cable must
be able to carry combined weld output of all modules using the Common Work Connection terminal (see Table 3-1 for proper cable size).
Tools Needed:
1-1/4 in
ST-144 568-C
Table 3-1. Common Work Cable Size
Common Work Cable Sizes At Main Transformer
Rated Welding Current
OM-218 Page 14
Cable Length
Cable Size
50 Feet
2 No. 3/0
100 Feet
2 No. 4/0
150 Feet
3 No. 3/0
200 Feet
3 No. 4/0
B. Parallel Module Connections
1
Cable Restraint
Route all cables under cable
restraint.
Y READ SAFETY BLOCKS at start of Section 3-5 before proceeding.
Separate Work Connections
See Section 3-4 for proper cable
size.
UNDERSIZED WELDING CABLES can cause fire.
2
Use single cables of adequate capacity to carry the total combined amperage of the paralleled modules (see Section 3-4) .
Securely cover common connections with proper insulating materials.
Set the Amperage Adjustment controls on
all paralleled modules to provide the same
output.
Negative (–) Weld Output
Terminal
3
Electrode Holder Cable
4
Positive (+) Weld Output
Terminal
5
Work Cable
6
Connection Point
For Electrode Negative (Straight
Polarity/DCEN), connect separate
cables of same size and length from
Positive (+) terminals to the work or
to a suitable connection point connecting to a single work cable.
Connect separate cables of same
size and length from Negative (–)
terminals to a suitable connection
point connecting to a single electrode holder cable.
For Electrode Positive (Reverse
Polarity/DCEP), reverse cable connections.
Securely cover connection with proper
insulating material.
Common Work Connections
6
1
Common Work Connection
Terminal
8
Common Work Cable
See Table 3-1 for proper size cable.
2
3
Separate Work
Connections
4
5
9
10
Common Work
Connections
7
7
8
9
Frame Connection Terminal
10 Jumper Link
For Electrode Negative (Straight
Polarity/DCEN), connect jumper
link across Positive (+) terminal and
Frame Connection 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.
For Electrode Positive (Reverse
Polarity/DCEP), connect jumper
link across Negative (–) terminal
and Frame Connection terminal for
each paralleled module, and connect separate cables of same size
and length from Positive (+) terminals to a suitable connection point
connecting to a single electrode
holder cable.
3
For common work connection, work cable must
be able to carry combined weld output of all modules using the Common Work Connection terminal (see Table 3-1 for proper cable size).
Tools Needed:
1-1/4 in
ST-085 152-D
OM-218 Page 15
3-6. Remote Amperage Control Receptacle
1
Remote Amperage Control
Receptacles RCX1 (“X”
Represents The Number Of
The Applicable Module 1–8)
The twistlock receptacle in each
module provides a connection point
for an optional remote amperage
control. To connect to one of these
receptacles, insert plug from remote amperage control and turn
clockwise.
1
ST-144 570-A / Ref. ST-174 143
3-7. Remote Contactor Control Connections (Optional)
Terminal strip 1T provides a connection point for connecting a normally open, momentary contact
switch for remote contactor control.
Y Turn Off polyweld system, and disconnect input power
before making contactor control connections.
Whenever the Remote Contactor switch is closed with
Power switch On button pressed, input power is applied
to all modules.
To connect a remote contactor
control, proceed as follows:
1
Terminal Strip 1T
2
Access Hole Location
Drill or punch a hole in lower right
rear panel to provide access to
terminal strip 1T. Hole size should
accept standard strain relief
connector.
Install strain relief into access hole.
3
Jumper Link
Remove jumper link.
4
Lead Connections
Route cord through strain relief and
connect leads to 1T as shown.
Polarity is not important. Connect
leads on other end of cord to a
suitable switch.
2
Close and secure rear panel access door.
1
4
Tools Needed:
3
3/8 in
Ref. ST-144 569-B
OM-218 Page 16
3-8. 115 Volts AC Duplex Receptacle
1
115 Volts AC Duplex
Receptacle RC2
This receptacle supplies up to 10
amperes of 115 volts ac power.
115V
10A
AC
115V
AC
OVERLOAD
BREAKER
The duplex receptacle is protected
from overload by Overload Breaker
CB1 (see Section 5-2).
CLOSED
OPEN
1
Ref. ST-144 570-A / Ref. SC-085 382
3-9. Connecting Input Power
A. Positioning Jumper Links
Y Turn Off polyweld system, and disconnect input power
before inspecting or installing.
230 VOLTS
460 VOLTS
575 VOLTS
1
2
TE3
TE2
TE3
TE2
TE3
TE2
S-006 233-A
Jumper links allow operation on
different input voltages and are
factory set for the highest input
voltage.
Check input voltage available at
site.
Open rear panel access door to
check jumper links.
1
Input Voltage Label
Look at jumper links and compare
link position with unit label.
2
Input Voltage Jumper Links
Move links to match input voltage.
For example, use 230 volts position
when 230 volts input power is
available.
Close rear panel access door or go
on to Section 3-9B.
Tools Needed:
3/8, 1/2 in
ssb5.1* 2/92 – Ref. ST-144 569-B
OM-218 Page 17
B. Connecting Input Power
Have only qualified persons make
this installation.
1
Y Turn Off polyweld system, and disconnect input
power before inspecting or installing.
Line Disconnect Device Of
Proper Rating
2
Input Conductors
3
Grounding Conductor
Select size and length using Section 3-10. Conductor rating must
comply with national, state, and
local electrical codes. Use lugs of
proper amperage capacity and correct hole size.
8
4
User-Supplied Strain Relief
Connector
Insert conductors through strain
relief.
1
9
3
5
Input Terminal Board
6
Line Terminals
7
Polyweld System Ground
Terminal
Connect grounding conductor to
ground terminal first. Then connect
input conductors to line terminals.
8
Disconnect Device Ground
Terminal
Install and connect grounding
conductor and input conductors in
conduit or equivalent to deenergized line disconnect device.
4
Connect grounding conductor first,
then line input conductors.
Be sure grounding conductor goes
to an earth ground.
7
2
6
Close rear panel access door.
5
9
Overcurrent Protection
Select type and size using Section
3-10. Install into deenergized line
disconnect device (fused disconnect switch shown).
Tools Needed:
1-1/16 in
3/8 in
ssb2.4* 1/94 – Ref. ST-144 569-B
3-10. Electrical Service Guide
Input Voltage
230
460
575
Input Amperes At Rated Output
170
85
68
Max Recommended Standard Fuse Or Circuit
Breaker Rating In Amperes
250
125
100
Min Input Conductor Size In AWG/Kcmil
1/0
4
6
163 (50)
307 (94)
320 (97)
4
6
8
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code (NEC).
OM-218 Page 18
S-0092J
SECTION 4 – OPERATION
4-1. Controls
1
2
1
Remote Amperage Control
Switch
2
Module Circuit Breaker (See
Section 5-2)
3
Amperage Adjustment Control
4
Power Switch
5
Pilot Light
3
4
5
ST-144 570-A
OM-218 Page 19
4-2. Amperage Adjustment Controls
1
Control can be adjusted
while welding.
Remote Amperage Control
Switch
For front panel control of a module,
place switch on that module in Off
position.
For remote control, place switch in
On position. See Example below.
1
2
Amperage Adjustment Control
Use control at each module to
select weld amperage for that module. The numbers are weld
amperes.
3
Remote Hand Control
2
Example Of Combination Remote Amperage Control
3
Min (35 A)
Max (125 A)
Set Switch
Set Desired Maximum Amperage
Adjust Remote Control
Ref. ST-174 143
4-3. Power Switch Push Buttons And Pilot Light
1
2
1
Pilot Light
2
Power On Push Button
Press button to turn unit, pilot light,
and fan motors On.
3
Power Off Push Button
Press button to turn unit, pilot light,
and fan motors Off.
3
OM-218 Page 20
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
Y Turn Off polyweld system, and disconnect input power
before inspecting, maintaining, or servicing.
6 Months
3 Months
See
Section
3-5
––
Clean
And
Tighten
Weld
Terminals
OR
Tape Or
Replace
Cracked
Cables
During Heavy Service,
Clean Monthly
––
Replace
Unreadable
Labels
Blow Out
Or
Vacuum
Inside
Fan
Motor
Sealed
Bearings
– No Oil
Needed
––
9
ST-144 567-A
5-2. Overload Protection
A. Overload Circuit Breaker CB1 And Module Circuit Breakers CB11 Through CB81
Y Turn Off polyweld system, and disconnect input power before inspecting, maintaining, or servicing.
1
Overload Circuit Breaker CB1
Circuit breaker CB1 protects the
115 volts ac windings of control
transformer T3 from overload. If
CB1 opens, the 115 volts ac duplex
receptacle RC2 would not work.
Manually reset CB1.
2
2
Module Circuit Breakers CB11
Through CB81
The control circuitry in each of the
eight modules is protected from
overload by a circuit breaker CBX1
(“X” represents the number of the
applicable module, 1–8). If a module circuit breaker opens, output
from the affected module would
drop to minimum and can not be
regulated. Manually reset the affected breaker.
115V
10A
AC
115V
AC
OVERLOAD
BREAKER
CLOSED
OPEN
1
ST-144 570-A / Ref. ST-174 143 / Ref. SC-085 382
OM-218 Page 21
B. Control Fuses F3 And F4
Y Turn Off polyweld system, and disconnect input power before inspecting, maintaining, or servicing.
Turn Off polyweld system and disconnect input power.
1
Input Terminal Board
2
Fuses F3 And F4 Location
3
Fuse F3 Or F4 (See Parts List
For Rating)
4
Fuse Holder
Check F3 or F4, and replace if
needed. Use proper tool when removing fuse.
4
Close rear access door.
3
Tools Needed:
3/8 in
1
2
Ref. ST-144 569-B / Ref. ST-146 126-C
C. Module Fuse Links F11 And F12 Through F81 And F82
Y Turn Off polyweld system, and disconnect input power before inspecting,
maintaining, or servicing.
1
2
Turn Off polyweld system and disconnect input power.
1
Fuse Links (Odd Number
Modules)
2
Fuse Links (Even Number
Modules)
Each of the eight modules is protected from overload by a pair of
link-type fuses FX1 and FX2 (“X”
represents the number of the applicable module, 1–8). If one fuse link
for a module 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), proceed as
follows: Remove upper rear panel.
Check fuse(s), and replace if necessary. Reinstall upper rear panel.
Tools Needed:
3/8, 1/2 in
ST-800 479 / ST-155 300
5-3. Blank Module Panel
Y Turn Off polyweld system, and disconnect input power
before inspecting, maintaining, or servicing.
A blank module panel is included with each polyweld system. If a module is removed, install the blank module panel in
the location where the module was removed before using the remaining modules. This panel prevents the touching of
inside parts and wires, and ensures proper air flow through the polyweld system.
OM-218 Page 22
5-4. Troubleshooting
Y Turn Off polyweld system, and disconnect input power
before inspecting, maintaining, or servicing.
Trouble
Remedy
No weld output from any module; fan Place line disconnect device in On position (see Section 3-9).
motors off; pilot light off.
Check line fuse(s), and replace if needed. Reset circuit breakers (see Section 3-9).
Check for proper input connections (see Section 3-9).
Check position of input voltage jumper links (see Section 3-9).
Be sure power switch is On (see Section 4-3).
Check fuse F3 and/or F4, and replace if needed (see Section 5-2).
Have Factory Authorized Service Station/Service Distributor check Start/Stop push buttons PB1/PB2
and replace if necessary.
No weld output from any module; fan Thermostat TP1 open (overheating). Allows fans to run; thermostat closes when unit has cooled (see
motors on; pilot light off.
Section 5-2).
No weld output from any module; fan Have Factory Authorized Service Station/Service Distributor check contactor W and replace if needed.
motors on; pilot light on.
Limited output and low open circuit volt- Check incoming power for correct voltage. Replace line fuse if open or reset circuit breaker (see Section
age from All modules.
3-9).
Check position of input voltage jumper links (see Section 3-9).
No weld output from one module only.
Check fuse links, and replace if needed (see Section 5-2).
Low weld output from one module only. Place Remote Amperage control switch in Off position or connect remote amperage control to Remote
No amperage control.
Amperage Control receptacle (see Section 4-2).
Check module fuse link, and replace if needed (see Section 5-2).
Reset module circuit breaker (see Section 5-2).
Module thermostat open (overheating). Allow module to cool down; thermostat closes when module has
cooled (see Section 5-2).
Erratic weld output.
Tighten all weld cable connections (see Section 3-5).
Check for proper size and type of cable (see Section 3-9).
Check for proper input and output connections (see Sections 3-9 and 3-5).
Use dry, properly stored electrodes.
No weld output at 115 volts ac duplex Reset overload circuit breaker CB1 (see Section 5-2).
receptacle.
Check fuse F3 and/or F4, and replace if needed (see Section 5-2).
Fan motor(s) does not run when On Check fuse F3 and/or F4, and replace if needed (see Section 5-2).
push button is pressed.
Have Factory Authorized Service Station/Service Distributor check control relay CR1 and fan motor FM1
or FM2.
For GTAW, wandering arc – poor control Select proper size tungsten (see Section 7-1).
of direction of arc.
Properly prepare tungsten (see Sections 7-2 or 7-3).
Tungsten electrode oxidizing and not re- Shield weld zone of drafts.
maining bright after conclusion of weld.
Properly prepare tungsten (see Sections 7-2 or 7-3).
Replace torch parts if water has leaked into torch.
OM-218 Page 23
SECTION 6 – ELECTRICAL DIAGRAM
Figure 6-1. Circuit Diagram For Polyweld System
OM-218 Page 24
SD-082 527-C
OM-218 Page 25
SECTION 7 – SELECTING AND PREPARING
TUNGSTEN ELECTRODE
gtaw 7/97
NOTE
For additional information, see your distributor for a handbook on the Gas
Tungsten Arc Welding (GTAW) process.Wear clean gloves to prevent
contamination of tungsten electrode.
7-1. Selecting Tungsten Electrode
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC – Argon – Electrode
Negative/Straight Polarity
DC – Argon – Electrode
Positive/Reverse Polarity
AC – Argon – Using
High Frequency
AC – Argon – Balanced
Wave Using High Freq.
.010”
Up to 15
*
Up to 15
Up to 10
.020”
5-20
*
5-20
10-20
Pure Tungsten
(Green Band)
.040”
15-80
*
10-60
20-30
1/16”
70-150
10-20
50-100
30-80
3/32”
125-225
15-30
100-160
60-130
1/8”
225-360
25-40
150-210
100-180
5/32”
360-450
40-55
200-275
160-240
3/16”
450-720
55-80
250-350
190-300
1/4”
720-950
80-125
325-450
250-400
.010”
Up to 25
*
Up to 20
Up to 15
.020”
15-40
*
15-35
5-20
.040”
25-85
*
20-80
20-60
1/16”
50-160
10-20
50-150
60-120
3/32”
135-235
15-30
130-250
100-180
1/8”
250-400
25-40
225-360
160-250
5/32”
400-500
40-55
300-450
200-320
2% Thorium Alloyed
Tungsten (Red Band)
3/16”
500-750
55-80
400-500
290-390
1/4”
750-1000
80-125
600-800
340-525
.010”
*
*
Up to 20
Up to 15
.020”
*
*
15-35
5-20
.040”
*
*
20-80
20-60
1/16”
*
*
50-150
60-120
3/32”
*
*
130-250
100-180
Zirconium Alloyed Tungsten (Brown Band)
1/8”
*
*
225-360
160-250
5/32”
*
*
300-450
200-320
3/16”
*
*
400-550
290-390
1/4”
*
*
600-800
340-525
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
OM-218 Page 26
7-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding
1
2
Tungsten Electrode
Balled End
Y Understand and
follow
safety symbols at start of
Section 8-1 before preparing
tungsten.
1
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher than what is recommended for a given electrode diameter (see Section 7-1), or a dc
electrode positive amperage.
1-1/2 Times
Electrode Diameter
2
Ref. S-0161
7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding
1
1
2
2
Tungsten Electrode
Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before welding. Do not use wheel for other jobs
or tungsten can become contaminated causing lower weld quality.
2-1/2 Times
Electrode Diameter
1
2
3
1
2
Stable Arc
Flat
Diameter of this flat determines
amperage capacity.
3
4
Grinding Wheel
Straight Ground
1
2
3
4
Arc Wander
Point
Grinding Wheel
Radial Ground
4
Ideal Tungsten Preparation – Stable Arc
1
2
3
4
Wrong Tungsten Preparation – Wandering Arc
Ref. S-0161 / Ref. S-0162
OM-218 Page 27
SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW)
8-1. Positioining The Torch
Y Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
3
1
Workpiece
Make sure workpiece is clean
before welding.
2
2
Work Clamp
Place as close to the weld as
possible.
4
3
4
5
90°
Torch
Filler Rod (If Applicable)
Tungsten Electrode
Select and prepare tungsten
according to Sections 7-1, and 7-2
or 7-3.
1
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
Arc length is the distance from the
tungsten to the workpiece.
10–15°
As a general guide, start with an
extension and arc length equal to
diameter of tungsten.
4
5
10–25°
ST-161 892
8-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
Tilt torch
Remove rod
15°
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
OM-218 Page 28
8-3. Positioning Torch Tungsten For Various Weld Joints
90°
Butt Weld And Stringer Bead
70°
20°
20°
“T” Joint
70°
10°
20°
40°
Lap Joint
70°
20°
30°
90°
Corner Joint
70°
20°
ST-162 003 / S-0792
OM-218 Page 29
SECTION 9 – PARTS LIST
. Hardware is common and
not available unless listed.
11
12 13
10
14
15
1
2
16
8
3
9
7
6
5
4
17
18
19
6
21
23
22
24
25
Fig 9-4
20
5
Fig 9-3
8
ST-144 531-C
Figure 9-1. Main Assembly (Section A)
OM-218 Page 30
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly (Section A)
. . . 1 . . . . FM1,2 . . . . 032 605
. . . 2 . . . . . . . . . . . . . . . 071 763
. . . 3 . . . . . . . . . . . . . . . 014 544
. . . 4 . . . . . . . . . . . . . . . 147 558
. . . 5 . . . . . . . . . . . . . . . 087 125
. . . 6 . . . . . . . . . . . . . . . 086 677
. . . 7 . . . . . . . . . . . . . . . 144 583
. . . 8 . . . . . . . . . . . . . . . 086 678
. . . 9 . . . . . . . . . . . . . . . 032 473
. . . 10 . . . . . . . . . . . . . . . 032 474
. . . 11 . . . . . MA,Z . . . . 099 480
. . . 12 . . . . . . . . . . . . . . . 084 932
. . . . . . . . . . . TP11 . . . . 162 375
. . . 13 . . . . . . . . . . . . . . . 033 947
. . . 14 . . . . . . . . . . . . . . . 097 947
. . . . . . . . . . . . . . . . . . . . . 097 948
. . . . . . . . . . . . . . . . . . . . . 097 949
. . . 15 . . . . . SR11 . . . . 210 352
. . . 16 . . . . . . . . . . . . . . . 086 679
. . . 17 . . . . . . . . . . . . . . . 087 178
. . . 18 . . . . . . . . . . . . . . . 102 207
. . . 19 . . . . . . . . . . . . . . . 087 124
. . . . . . . . . . . . . . . . . . . . . 020 279
. . . . . . . . . . . . . . . . . . . . . 087 318
. . . 20 . . . . . . T1 . . . . . 128 492
. . . 21 . . . . . . . . . . . . . . . 088 713
. . . 22 . . . . . . . . . . . . . . . 088 712
. . . . . . . . . . . TP1 . . . . . 026 181
. . . . . . . . . . . . . . . . . . . . . 103 723
. . . 23 . . . . . . . . . . . . . . . 173 513
. . . 24 . . . . . . . . . . . . . . . . Fig 9-3
. . . 25 . . . . . . . . . . . . . . . . Fig 9-4
. . . . . . . . . . . . . . . . . . . . . 086 435
. . . . . . . . . . . . . . . . . . . . . 603 732
. . MOTOR, cap perm SP 1/4hp 230VAC 1625RPM . . . . . . . . . . . . . . . . . . .
. . FRAME, mtg fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CHAMBER, plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLADE, fan 20 in 3wg 21deg .500 bore CCW . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COLUMN, corner LH front & RH rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COLUMN, corner RH front & LH rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AMPLIFIER & STABILIZER, mag (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . STABILIZER, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, control dc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, ac front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, ac center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, ac rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER ASSEMBLY, si diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rear upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rear lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLATE, adapter power cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FRAME, mtg module center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush .750dia x .281mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush 1.000dia x .203mtg hole . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, pwr main (230/460/575) (consisting of) . . . . . . . . . . .
. . . . COIL, pri/sec top (230/460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . COIL, pri/sec bottom (230/460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SHIM, endbell foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREEN, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front module w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front lower w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL BLANK, module front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, brs hex .750-10 full hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
2
2
1
2
1
1
8
1
1
1
1
1
1
1
2
1
1
2
6
6
1
3
3
1
4
1
8
1
1
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-218 Page 31
. Hardware is common and
not available unless listed.
5
1
4
6
2
7
3
8
9
10
ST-144 660
Figure 9-2. Main Assembly (Section B)
OM-218 Page 32
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-2. Main Assembly (Section B)
. . . 1 . . . . . CR1 . . . . 194 307
. . . 2 . . . . . . T3 . . . . . 092 324
. . . 3 . . . . . . 1T . . . . . 038 617
. . . . . . . . . . . . . . . . . . . . . 038 620
. . . 4 . . . . . . . . . . . . . . . 070 404
. . . 5 . . . . . F3,4 . . . *012 664
. . . 6 . . . . . . . . . . . . . . . 010 117
. . . 7 . . . . . TE1 . . . . . 027 096
. . . . . . . . . . . . . . . . . . . . . 038 974
. . . . . . . . . . . . . . . . . . . . . 601 836
. . . . . . . . . . . . . . . . . . . . . 010 915
. . . . . . . . . . . . . . . . . . . . . 038 890
. . . . . . . . . . . . . . . . . . . . . 038 994
. . . . . . . . . . . . . . . . . . . . . 038 620
. . . . . . . . . . . . . . . . . . . . . 038 622
. . . . . . . . . . . . . . . . . . . . . 601 838
. . . . . . . . . . . . . . . . . . . . . 010 910
. . . . . . . . . . . . . . . . . . . . . 602 213
. . . . . . . . . . . . . . . . . . . . . 038 804
. . . . . . . . . . . . . . . . . . . . . 010 913
. . . 8 . . . . F11-82 . . . 012 237
. . . . . . . . . . . . . . . . . . . . . 038 888
. . . . . . . . . . . . . . . . . . . . . 038 205
. . . . . . . . . . . . . . . . . . . . . 010 915
. . . . . . . . . . . . . . . . . . . . . 601 836
. . . . . . . . . . . . . . . . . . . . *012 207
. . . . . . . . . . . . . . . . . . . . . 602 241
. . . . . . . . . . . . . . . . . . . . . 602 207
. . . . . . . . . . . . . . . . . . . . . 601 835
. . . . . . . . . . . . . . . . . . . . . 010 913
. . . . . . . . . . . . . . . . . . . . . 038 887
. . . . . . . . . . . . . . . . . . . . . 177 711
. . . 9 . . . . . . W . . . . . 099 044
. . . . . . . . . . . . . . . . . . . . . 048 599
. . . 10 . . . . . . T2 . . . . . 144 589
. . . . . . . . . . . . . . . . . . . . . 015 722
. . CONTACTOR, def prp 40A 3P 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, kVA 1 115-230/460/575 . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 30A 2P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, fuse crtg 30A 600V 1P w/clips . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FUSE, crtg 15A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, stl .625 OD x .156 wall x 2.625 lg . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL ASSEMBLY, pri 3ph dual voltage (consisting of) . . . . . . . . .
. . . . TERMINAL BOARD, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . .
. . . . STUD, pri bd brs .250-20 x 2.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LINK, jumper pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BLOCK, term 30A 5P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, brs hex .375-16 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat stl SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STUD, brs .375-16 x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . .
. . FUSE PANEL, module (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STUD, pri bd brs .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PANEL, fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . .
. . . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FUSE, link 200A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat stl SAE .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, lock stl split .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . .
. . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, cover fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONTACTOR, sz 3-1/2 3P 110-120/220-240 (consisting of) . . . . . . . . .
. . . . COIL, cntor 115/230V sz 3-1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, kVA 2 115-230/460/575 . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, rbr 1.250 ID x 1.500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
4
1
1
30
15
18
6
2
2
9
3
3
3
4
4
10
1
10
14
4
4
4
4
4
4
4
1
1
1
2
*Recommended Spare Parts.
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-218 Page 33
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-3. Panel, Front Module w/Components (Fig 9-1 Item 24)
. . . 1 . . . . . . . . . . . . . . . 034 253
. . . . . . . . . . . . . . . . . . . . . 032 477
. . . 2 . . . . . . . . . . . . . . . 038 978
. . . 3 . . . . . . . . . . . . . . . 026 758
. . . 4 . . . . . . . . . . . . . . . 177 618
. . . 4 . . . . . . . . . . . . . . . 174 143
. . . 5 . . . . . . . . . . . . . . . 098 899
. . . 6 . . . . . SR12 . . . . 035 704
. . . 7 . . . . . S13 . . . . *011 609
. . . 8 . . . . . . . . . . . . . . . 039 047
. . . 9 . . . . . . . . . . . . . . . 099 255
. . . 10 . . . . . . . . . . . . . . . 039 046
. . . . . . . . . . . . . . . . . . . . . 601 879
. . . . . . . . . . . . . . . . . . . . . 039 044
. . . . . . . . . . . . . . . . . . . . . 601 880
. . . . . . . . . . . . . . . . . . . . . 039 049
. . . . . . . . . . . . . . . . . . . . . 039 040
. . . . . . . . . . . . . . . . . . . . . 039 045
. . . . . . . . . . . . . . . . . . . . . 601 976
. . . 11 . . . . . CB11 . . . . 083 432
. . . 12 . . . . . R11 . . . . . 030 653
. . . 13 . . . . . RC11 . . . . 039 607
. . . . . . . . . . . . . . . . . . . . . 605 797
. . . 14 . . . . . . . . . . . . . . . 010 828
. . . 15 . . . . . . . . . . . . . . . 097 926
. . DOOR, access pwr output (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR, cover secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOOT, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLATE, front module 50/60 HZ models . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLATE, front module 60 HZ models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, tgl SPDT 156A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output red (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output neutral (consisting of) . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, pwr output black (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, stl .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, term bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, stl hex jam .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TERMINAL BOARD, red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TERMINAL BOARD, neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, cap stl hexhd .5001–13 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . .
. . RHEOSTAT, WW 150W 15 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECEPTACLE, twlk 3P3W 20A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLUG, twlk 3P3W 20A 120V Arrow Hart 6312
. . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and
1
1
8
7
not available unless listed.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
9
6
10
5
11
4
1
3
2
12
13
15
14
ST-155 304-C
Figure 9-3. Panel, Front Module w/Components
*Recommended Spare Parts.
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-218 Page 34
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-4. Panel, Front Lower w/Components (Fig 9-1 Item 25)
. . . 1 . . . . . . . . . . . . . . +086 855 . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . . 085 500 . . LABEL, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . 004 449 . . RING, spacer switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . . 204 360 . . LIGHT, ind white lens (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . PL1 . . . . *027 633 . . . . BULB, incand bayonet base 8V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . . 204 361 . . . . LENS, light ind white . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . Start . . . . 011 033 . . PUSH BUTTON, operator black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . Start . . . . 011 035 . . CONTACT BLOCK, NO PB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . Stop . . . . 011 036 . . CONTACT BLOCK, NC PB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . Stop . . . . 011 034 . . PUSH BUTTON, operator red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . . 016 585 . . COVER, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . RC2 . . . . 604 176 . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V P & S 5266DF
. . . 14 . . . . . CB1 . . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . . 026 758 . . BOOT, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . 038 805 . . COVER, rcpt weatherproof duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . . 004 450 . . BOOT, PB red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . 004 451 . . BOOT, PB black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . .
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
. Hardware is common and
1
not available unless listed.
5
2
6
Includes
Item 7
8
3
9
4
10
11
12
13
14
7
18
17
19
16
15
Figure 9-4. Panel, Front Lower w/Components
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
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-218 Page 35
Notes
OM-218 Page 36
Effective January 1, 2002
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 6/02
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 2002 Miller Electric Mfg. Co.
5/02
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