Miller | LE109804 | Owner Manual | Miller MAXSTAR 300 SD User manual

Miller MAXSTAR 300 SD User manual
OM-2222
189 533Y
January 2004
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
230/460 Volt Models W/AutolinkR
400 Volts Models
Arc Welding Power Source
R
Maxstar 300 SD,
DX And LX
And Non-CE Models
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual 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.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . . 7
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS (CE Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Manufacturer’s Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-2. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-5. 115 Volts AC Duplex Receptacle, Circuit breaker (Optional) And Power Switch . . . . . . . . . . . . . . . . . . 16
4-6. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-7. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-8. Remote Program Select Inputs (Optional For DX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-9. Automation Connection (LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-10. Typical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-11. Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-12. TIG HF Impulse/ Lift-Arc DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . . 20
4-13. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-14. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-15. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-2. Encoder Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-3. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-4. Ammeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-5. Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-6. Polarity Control (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-7. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-8. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-9. Pulser Control (DX And LX Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-10. Sequencer Controls (DX, LX And All CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-12. AC Waveshape (Dynasty Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5-13. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) (All Models) . . . . . . . . . . . . . . . . . 31
5-14. Memory (Program Storage Locations 1-4) (DX And LX Models If Available) . . . . . . . . . . . . . . . . . . . . . 32
5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A Preflow Control On
The Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-16. Factory Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5-17. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SECTION 6 − ADVANCED FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Programable TIG Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Output Control And Trigger Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Arc Timer/Counter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Lockout Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only) . . . . . . . . . . . . . . . . . . . .
6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − SELECTING AND PREPARING
TUNGSTEN ELECTRODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Selecting Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Safety Information About Tungsten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Typical DC - GTAW 16 Gauge Stainless Steel Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Lift-ArcE And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-5. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . .
12-2. Electrode and Amperage Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3. Stick Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4. Striking an Arc − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-5. Striking an Arc − Tapping Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-6. Positioning Electrode Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-7. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-8. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-11. Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-12. Lap Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-13. Tee Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-14. Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
36
36
39
47
48
51
52
53
53
53
54
55
56
58
58
58
59
60
60
60
61
62
62
63
64
65
66
67
67
68
69
69
69
70
70
70
72
72
72
73
76
Declaration of Conformity For
European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit.)
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
Maxstar R 300 SD, DX, LX
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Capability Directives: 89/336, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(December 1996 − Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
European Contact:
Telephone:
Fax:
dec_con1_11/02
Mr. Danilo Fedolfi, Managing Director
ITW WELDING PRODUCTS ITALY S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98290-203
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
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.
Y Marks a special safety message.
. Means “Note”; not safety related.
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 1-5. 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.
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.
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 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.
Return To Table Of Contents
OM-2222 Page 1
ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
Arc rays 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).
HOT PARTS can cause severe burns.
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.
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.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
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-2222 Page 2
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.
Return To Table Of Contents
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. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Return To Table Of Contents
OM-2222 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. 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-2222 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.
Return To Table Of Contents
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
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. Tout matériel mal installé ou mal
mis à la terre présente un danger.
Il subsiste un 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
énoncées à la section Entretien avant de toucher les pièces.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif 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. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’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 Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’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 d’une autre machine.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
Revenez à la table des matières
OM-2222 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
D
D
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LE SOUDAGE peut causer un incendie ou une explosion.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer 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 protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer 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 agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’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 que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause 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 porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-2222 Page 6
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, 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 poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur 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 de la CGA,
mentionnées dans les normes de sécurité.
Revenez à la table des matières
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés 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 dimensionnée et protégée avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique 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 imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives 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 FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
Revenez à la table des matières
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-2222 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-2222 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
Revenez à la table des matières
SECTION 3 − DEFINITIONS (CE Models Only)
3-1. Warning Label Definitions
Warning! Watch Out! There are possible
hazards as shown by the symbols.
1
Electric shock from welding electrode
or wiring can kill.
2
2.1
2.2
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
2.3
3
1.2 Protect yourself from electric shock
by insulating yourself from work and
ground.
3.1
3.2
1.3 Disconnect input plug or power before
working on machine.
1
1.1
2
2.1
3
3.1
1.2
Breathing welding fumes can be
hazardous to your health.
Keep your head out of the fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove fumes.
Welding sparks can cause explosion
or fire.
Keep flammables away from welding.
Do not weld near flammables.
Welding sparks can cause fires. Have
a fire extinguisher nearby, and have a
watchperson ready to use it.
1.3
2.2
2.3
3.2
4
3.3 Do not weld on drums or any closed
containers.
4
Arc rays can burn eyes and injure
skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
5
Become trained and read the
instructions before working on the
machine or welding.
6
Do not remove or paint over (cover)
the label.
4.1
5
3.3
6
197 310-A
1/96
Return To Table Of Contents
OM-2222 Page 9
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
2
1
2
4
3
5
V
V
> 60 s
V
3
4
5
6
S-185 836
7
6
9
8
7
8
9
1
1
2
3
∠ = <60 °
4
∠
5
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Hazardous voltage remains
on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.
Always wait 60 seconds after
power is turned off before
working on unit, OR
Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
When power is applied failed
parts can explode or cause
other parts to explode.
Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
Always wear long sleeves and
button your collar when
servicing unit.
After taking proper
precautions as shown,
connect power to unit.
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling equipment can cause
injury and damage to unit.
Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
Use a proper cart to move
unit.
Do not use one handle to lift
or support unit.
S-179 309-A
2
3
4
5
1/96
OM-2222 Page 10
Return To Table Of Contents
3-2. Manufacturer’s Rating Labels
. For label location
see Section 4-4.
Manufacture’s Rating Label For Non-CE Models
Ref. ST-189 529-C
Manufacture’s Rating Label For CE Models
ST-188 153-A
Return To Table Of Contents
OM-2222 Page 11
3-3. Symbols And Definitions
A
Amperes
Panel−Local
V
Volts
Input
Output
Circuit Breaker
Remote
Protective Earth
(Ground)
Postflow Timer
Preflow Timer
On
Off
Positive
Alternating
Current
Gas Input
Gas Output
Duty Cycle
Direct Current
Line Connection
X
U1
U0
Primary Voltage
IP
Degree Of
Protection
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
3 Phase Static Frequency
Converter-Transformer-Rectifier
I1max
Rated Maximum
Supply Current
Lift-Arc (GTAW)
S
Seconds
Negative
I2
Rated Welding
Current
U2
Conventional Load
Voltage
I1eff
Maximum Effective
Supply Current
Rated No Load
Voltage (Average)
Pulse Background
Amperage
Initial Amperage
Increase/Decrease
Of Quantity
Normal Trigger Operation (GTAW)
Two-Step Trigger
Operation (GTAW)
Four-Step Trigger
Operation (GTAW)
Percent
Hertz
Recall From
Memory
Arc Force (DIG)
Impulse Starting
(GTAW)
Final Slope
Final Amperage
Pulse Percent
On Time
Initial Slope
Contactor Control
(Stick)
Pulser
TIG Weld Amps
And Peak Amps
While Pulsing
Pulse Frequency
Adjust
Process
Output
Sequence
Hz
Unit may be used
in environments
with increased
hazard of electric
shock
OM-2222 Page 12
Return To Table Of Contents
SECTION 4 − INSTALLATION
4-1. Specifications
A. For Multivoltage Units
Input
Power
Rated Output at
60% Duty Cycle
ThreePhase
250 A @ 30 VDC,
60% Duty Cycle
SinglePhase
200 A @ 28 VDC,
60% Duty Cycle
Welding
Amperage
Range
Max.
Open-Circuit
Voltage
95∇
5 - 300
6 -10♦
Amperes Input At
Rated Output, 60Hz
KVA
KW
Dimensions
H: 17 in (432 mm)
230
460
25.4
0.23*
16.2
0.14*
12.8
0.11*
8.8
0.06*
-−
9.3
0.11*
6.8
0.06*
Net
Weight
W: 12-1/2 in (318 mm)
95∇
5 - 300
6 - 10♦
40.2
0.32*
D: 24 in (610 mm)
82 lb
(37 kg)
100 lb
(45 kg)
w/aux.
power
*While idling
♦Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected (see Section 6-6).
∇Normal open-circuit voltage (95 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-6).
Note: This unit is equipped with Auto-LinkR. Auto-Link is an internal inverter power source circuit that automatically links the power source to
the primary voltage being applied (230 to 460 V), without the need for manually linking primary voltage terminals.
B. For Single Voltage Units
Rated Output at
60% Duty Cycle
250 A @ 30 VDC,
60% Duty Cycle
Welding
Amperage
Range
Max.
Open-Circuit
Voltage
95∇
5 - 300
6 - 10♦
Amperes Input
At Rated Output,
50Hz - Three-Phase 400 V
KVA
KW
Dimensions
H: 17 in (432 mm)
16.9
0.15*
11.7
0.10*
8.6
0.03*
W: 12-1/2 in (318 mm)
D: 24 in (610 mm)
Net
Weight
82 lb
(37 kg)
100 lb
(45 kg)
w/aux.
power
*While idling
♦Low open-circuit voltage while in TIG Lift Arct, or while in Stick with low open-circuit voltage selected (see Section 6-6).
∇Normal open-circuit voltage (95 volts) is present while in Stick with normal open-circuit voltage selected (see Section 6-6).
4-2. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of welding
power source. Curves of other settings fall between curves shown.
ST-190 014
Return To Table Of Contents
OM-2222 Page 13
4-3. Duty Cycle And Overheating
Duty Cycle is the percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 7-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or voltage, or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
250 A @ 60% Duty Cycle For Three-Phase Models
200 A @ 60% Duty Cycle For Single-Phase Models
6 Minutes Welding
4 Minutes Resting
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
ST-186 863 / ST-190 012
OM-2222 Page 14
Return To Table Of Contents
4-4. Selecting A Location
1
Lifting Handles
Use handles to lift unit.
Dimensions And Weight
82 lb (37 kg) − 100 lb (45 kg) w/aux power
2
Hand Cart
Use cart or similar device to move
unit.
24 in
(610 mm)
3
Rating Label
Use rating label to determine input
power needs.
17 in
(432 mm)
4
5
Plate Label
Line Disconnect Device
Locate unit near correct input
power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
12-1/2 in
(318 mm)
Movement
Y Do not move or operate unit
where it could tip.
1
1
2
Location And Airflow
5
3
18 in
(460 mm)
4
18 in
(460 mm)
ST-802 137-A
Return To Table Of Contents
OM-2222 Page 15
4-5. 115 Volts AC Duplex Receptacle, Circuit breaker (Optional) And Power Switch
1
1
2
2
3
AC Duplex Receptacle
115 V 10 A for 230/460 volt models.
115 V 7 A for 400 volt models.
Circuit Breaker CB1
CB1 protects duplex receptacle
from overload.
Press button to reset breaker.
3
Power On/Off Switch
Ref. ST-801 866
4-6. Weld Output Terminals And Selecting Cable Sizes
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Weld Output
Terminals
Y Turn off power before
connecting to weld output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 2/0
(2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
−
10 − 100% Duty Cycle
+
Output Receptacles
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger
cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-2222 Page 16
Return To Table Of Contents
S-0007-E−
4-7. Remote 14 Receptacle Information
Socket*
A
B
K
Socket Information
J
I
A
Contactor control 24 volts dc.
B
Contact closure to A completes 24 volts dc
contactor control circuit and enables output.
C
Output to remote control; 0 to +10 volts dc output
to remote control.
D
Remote control circuit common.
E
0 to +10 volts dc input command signal from
remote control.
A/V
F
Current feedback; +1 volt dc per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt dc per 10 volts output.
GND
K
Chassis common.
24 VOLTS DC
H
C L N
M
D
G
E F
OUTPUT
CONTACTOR
REMOTE
OUTPUT
CONTROL
ST-802 137
*The remaining sockets are not used.
Note: If a remote hand control (RHEA-14) is connected to this Remote 14 receptacle, some current value must be set on the remote control
when the welding power source is turned on. If the remote control is turned off when the welding power source is turned on, the remote control
will not function. To correct this situation, turn the welding power source off, set some value on the remote control, and turn the welding power
source on.
Return To Table Of Contents
OM-2222 Page 17
4-8. Remote Program Select Inputs (Optional For DX Models)
10-Pin Receptacle RC2
Pin Designations 0 = No Connection /
1 = Connected To Ground (Pin G)
X= Do Not Care
Function
A
B
C
D
J
I
H
C
F
E
D
No Remote Control
0
0
X
X
Stick EP Of Current Program
1
0
X
X
Program 1 Stick EP
1
1
0
0
Program 2 Stick EP
1
1
0
1
Program 3 Stick EP
1
1
1
0
Program 4 Stick EP
1
1
1
1
Program 1 TIG EN
0
1
0
0
Program 2 TIG EN
0
1
0
1
Program 3 TIG EN
0
1
1
0
Program 4 TIG EN
0
1
1
1
G
F
E
ST-802 137-A
*The remaining sockets are not used.
Socket A
Contactor control, 24 volts dc
Socket B
Contact closure to A, completes 24 volts dc
contactor control circuit and enables output
Socket G
Chassis Ground
Socket I**
Valid arc collector (see Section 4-10)
Socket J**
Valid arc emitter (see Section 4-10)
**Valid arc output is an open-collector transistor.
To use the Remote Process Select function for a given program, select the TIG process on the front panel while the desired program
is selected.
OM-2222 Page 18
Return To Table Of Contents
4-9. Automation Connection (LX Models)
Socket
F
J
D
Start/Stop
B
Gas
C
Output Disable
D
Chassis ground
E
Final slope − collector
F
Final slope − emitter
G
Pulse lockout − collector
H
Pulse lockout − emitter
I
Valid arc − collector
J
Valid arc − emitter
C
I
A
A
E
G
H
Socket Information For 10-Pin Receptacle RC2
B
ST-802 137-A
Definitions Of Inputs And Outputs
Inputs
A - Closure to D starts the weld cycle. Opening closure stops weld cycle. Durning 2T operation, a momentary closure (greater than 100 ms, but
less than 3/4 seconds) starts and stops weld output.
B - Closure to D turns on gas. This input will override Postflow, but if a Preflow time is entered, the Preflow cycle will time out before arc initiation.
C - Closure to D must be maintained at all times. If the closure between pins C and D is broken, an output disable occurs, Postflow begins to
time out, and HELP 13 will be displayed on the meters.
Outputs
Outputs are isolated open-collector transistors.
Final Slope - output is on when in Final Slope.
Pulse Lockout - output is on when in Initial Amperage, Initial Slope, Final Slope, Final Amperage, and when the pulse frequency is less than 10
Hz.
Arc On - output is on when the contactor is on and there is less than 50 load volts.
4-10. Typical Application
CR1
R
Typical 10-Pin Output
Coil resistance plus R
should be choosen to
limit current to 75 mA
CR1
To User Equipment
+
User supplied power
up to 27 volts DC peak
−
Collector
Emitter
Return To Table Of Contents
OM-2222 Page 19
4-11. Gas Connections
1
Gas Fitting
Fittings have 5/8-18 right-hand
threads.
2
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
3
4
2
3
4
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cfh (cubic feet
per hour).
1
Connect customer supplied gas
hose between regulator/flowmeter
and gas fitting on rear of unit.
Tools Needed:
5/8, 1-1/8 in
ST-801 866
4-12. TIG HF Impulse/ Lift-Arc DCEN (Direct Current Electrode Negative) Connections
Y Turn off power before making connections.
1
Negative (−) Weld Output
Terminal
Connect TIG torch to negative weld
output terminal.
2
Gas Out Connection
Connect torch gas hose to gas out
fitting.
3
Positive (+) Weld Output
Terminal
Connect work lead to positive weld
output terminal.
4
Remote 14 Receptacle
Connect desired remote control to
Remote 14 receptacle.
5
Gas In Connection
Connect gas hose from gas supply
to gas in fitting.
5
1
2
4
3
Tools Needed:
11/16 in, (21 mm for CE units)
Ref. ST-802 650-A
OM-2222 Page 20
Return To Table Of Contents
4-13. Stick DCEP (Direct Current Electrode Positive) Connections
Y Turn off power before making connections.
1
Negative (−) Weld Output
Terminal
Connect work lead to negative weld
output terminal.
1
2
Positive (+) Weld Output
Terminal
Connect electrode holder to positive weld output terminal.
3
2
Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Section 4-7).
3
Ref. ST-802 650
4-14. Electrical Service Guide
A. For Multivoltage Units
NOTE
Actual input voltage cannot exceed ± 10% of indicated required input voltage. If
actual input voltage is outside of this range, no output is available.
Three-Phase
Single-Phase
Input Voltage
Input Amperes At Rated Output
230
460
230
25
15.8
40.2
50
25
60
10
14
8
123 (38)
197 (60)
139 (42)
10
14
10
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes1
Normal Operating2
Min Input Conductor Size In AWG
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG
Reference: 1996 National Electrical Code (NEC).
S-0092J
Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a time delay fuse. Time-Delay fuses are UL class RK5.
2 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
Y Failure to follow these fuse and circuit breaker recommendations could create an electrical shock or fire hazard.
B. For Single Voltage Units
Input Voltage
400
Input Amperes At Rated Output
16.9
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes1
Normal Operating2
Min Input Conductor Size In AWG
25
14
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG
153 (47)
14
Reference: 1996 National Electrical Code (NEC).
S-0092J
Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a time delay fuse. Time-Delay fuses are UL class RK5.
2 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
Y Failure to follow these fuse and circuit breaker recommendations could create an electrical shock or fire hazard.
Return To Table Of Contents
OM-2222 Page 21
4-15. Connecting Input Power
Y Disconnect and lockout/tagout input power before connecting input conductors
from unit.
Y Have only qualified persons
make this installation.
Check input voltage available at
site.
3
1
2
1
See Section 4-14.
Green Or
Green/Yellow
For three-phase operation:
Y Always connect green or
green/yellow wire to supply
grounding terminal, never to
a line terminal.
1
1
Connect black, white, and red wires
(L1, L2, L3) to line terminals.
For single-phase operation: 230/460 volt models
Only
L1
L2
L3
Green Or
Green/Yellow
Line Disconnect Device
Input And Grounding
Conductors
Install conductors into a deenergized line disconnect device.
2
Y Always connect grounding
conductor first.
Y Always connect green or
green/yellow wire to supply
grounding terminal, never to
a line terminal.
L1
L2
3
4
5
6
2
Black And White Input
Conductor
Red Input Conductor
Insulation Sleeving
Electrical Tape
Insulate and isolate red conductor
as shown.
= GND/PE
Note: This unit is equipped with
Auto-LinkR. Auto-Link is an internal inverter power source circuit
that automatically links the power
source to the primary voltage being
applied (230 to 460 V), without the
need for manually linking primary
voltage terminals.
2
3
4
Green Or
Green/Yellow
6
5
2
input_2 3/96 - ST-802 138-A
OM-2222 Page 22
Return To Table Of Contents
Notes
Return To Table Of Contents
OM-2222 Page 23
SECTION 5 − OPERATION
5-1. Controls
3
1
2
9
10
4
5
6
7
8
ST-198 719 / ST-801 866
11
Rear Panel
. For all front panel switch pad controls:
4
Process Controls
8
Adjust Controls
press switch pad to turn on light and enable normal function.
See Section 5-7.
See Section 5-11.
NOTE: Green on nameplate indicates a TIG
function, Gray indicates a normal Stick function.
5
9
See Section 5-8.
For Amperage Control see Section 5-3.
6
For Spot Time Control see Section 5-13.
1
2
Encoder Control
Ammeter And Parameter Display
See Section 5-4.
3
Voltmeter
See Section 5-5.
OM-2222 Page 24
Output Controls
Pulser Controls (DX And LX
Models)
See Section 5-9.
7
Sequencer Controls (DX, LX And
All CE Models)
See Section 5-10.
Return To Table Of Contents
Amperage And Spot Time Control
10 Memory
See Section 5-14.
11 Power Switch
Use switch to turn unit On/Off.
5-2. Encoder Control
1
Encoder Control
Use control in conjunction with applicable front panel function switch
pad to set values for that function.
1
5-3. Amperage Control
1
2
3
3
2
See Section 5-16 for Amperage
control range.
Press Amperage switch pad, and
turn Encoder control to set weld
amperage. Weld amperage setting
is also peak amperage when Pulser
function is active (see Section 5-9).
1
Or
A (Amperage Control)
Encoder Control
Ammeter
Or
5-4. Ammeter And Parameter Display
1
1
Return To Table Of Contents
Ammeter
Displays actual amperage while
welding. Meter also displays preset
parameters for any of the following
units of measure when they are active: amperage, time, percentage or
frequency. The corresponding
LED, located directly below the ammeter, will also illuminate.
OM-2222 Page 25
5-5. Voltmeter
1
Volt Meter
Displays output or open circuit voltage. If output is off, the voltmeter will
display a series of three dashes
(-−−). Open circuit voltage is displayed if power is on and output is
available.
1
5-6. Polarity Control (Dynasty Models Only)
1
Polarity Control
Press switch pad until desired LED
is illuminated.
DC - Machine is set to DCEN (direct
current electrode negative) for TIG
welding, and to DCEP (direct current electrode positive) for Stick
welding.
AC - Use AC (alternating current)
for TIG and Stick welding.
1
OM-2222 Page 26
Return To Table Of Contents
5-7. Process Control
1
Process Control
Press switch pad until desired process LED is illuminated:
TIG HF Impulse - When selected,
a pulsed HF (non-contact) (see
Section 11-3) arc starting method is
activated. This method can be used
with either AC or DC TIG welding.
Make connections according to
Section 4-12.
1
TIG Lift-Arct - When selected, is
an arc starting method in which the
electrode must come in contact
with the workpiece to initiate an arc
(see Section 11-3). This method
can be used with either AC or DC
TIG welding. Make connections according to Section 4-12.
Stick (SMAW) - This method can
be used with either AC or DC Stick
welding. Make connections according to Section 4-13.
5-8. Output Control
1
1
Output Control
Press switch pad until desired parameter LED is illuminated.
RMT STD (Remote Standard)
Application: Use Remote Trigger
(Standard) when the operator desires
to use a foot pedal or finger amperage
control (see Section 6-2A).
NOTE: When a foot or finger remote
current control is connected to the
welding power source, initial amps,
initial slope, final slope, and final amps
are controlled at the remote control,
not at the welding power source.
only trigger input is functional (see
Section 6-2B).
NOTE: If On/Off only type trigger is
used, it must be a maintained switch.
All Sequencer functions become active, and must be set by the operator.
NOTE: This switch function can be reconfigured for 4T, 4T Momentary, Mini
Logic, or Spot control See Section
6-2C)
RMT 2T HOLD
ON
Application: Use Remote Trigger
Hold (2T) when long extended welds
are made. Remote Trigger Hold (2T)
can help to reduce operator fatigue.
Output will energize two seconds after
being selected.
If a foot or finger current control is connected to the welding power source,
Return To Table Of Contents
Application: Use Output On for Stick
(SMAW) welding, or for Lift-Arc without the use of a remote control (see
Section 6-2H).
OM-2222 Page 27
5-9. Pulser Control (DX And LX Models)
1
3
2
Pulser Control
Pulsing is available only while using
the TIG process, it cannot be selected if the Stick process (see Section 5-7) is active. Controls can be adjusted while welding.
Press switch pad to enable pulser.
ON - When illuminated, this LED indicates the pulser is on.
Press switch pad until desired parameter LED is illuminated.
To turn Pulser off, press and release
switch pad until the On LED turns off.
2
3
Encoder Control
Ammeter
Turn encoder (see Section 5-2) to select appropriate value for active pulse
parameter. Value selected is shown
on the ammeter (see Section 5-4).
Also, the ammeter LED for the corresponding unit of measure (%, A, s,
Hz) of the active parameter will be illuminated.
1
See Section 5-16 for all Pulser parameter ranges.
PPS (Pulses Per Second or Pulse
Frequency) - Control is used to determine appearance of weld bead.
PEAK t - The percentage of each
pulse cycle that can be spent at the
peak amperage level.
4
Percent (%) Peak
Time Control Setting
Balanced
Pulsed Output Waveforms
PPS
(50%)
Bkg Amp
Peak Amp
More Time
At Peak
Amperage
BKGND A (Background Amps) - Use
Background Amps control to set the
low pulse of the weld amperage,
which cools the weld puddle and affects overall heat input. Background
Amps is set as a percentage of peak
amperage.
4
Pulsed Output Waveforms
Example shows affect changing the
Peak Time control has on the pulsed
output waveform.
NOTE: Peak amperage is set using
the Amperage control (see Section
5-3). Peak amperage is the highest
welding amperage allowed to occur
in the pulse cycle. Weld penetration
varies directly with peak amperage.
(80%)
Application:
More Time
At
Background
Amperage
Pulsing refers to the alternating raising and lowering of the weld output at
a specific rate. The raised portions of
the weld output are controlled in
width, height, and frequency, forming
pulses of weld output. These pulses
and the lower amperage level between them (called the background
amperage) alternately heat and cool
the molten weld puddle. The combined effect gives the operator better
control of penetration, bead width,
crowning, undercutting, and heat input. Controls can be adjusted while
welding.
(20%)
Pulsing can also be used for filler material addition technique training.
OM-2222 Page 28
Return To Table Of Contents
5-10. Sequencer Controls (DX, LX And All CE Models)
1
3
2
Sequencer Control
Sequencing is available only while
using the TIG process, but is disabled if a remote foot or finger current control is connected to the Remote receptacle while in the RMT
STD mode. Sequencer parameters
cannot be selected if the Stick process (see Section 5-7) is active.
Press switch pad until desired parameter LED is illuminated.
4
Or
2
3
Or
Encoder Control
Ammeter
Turn encoder (see Section 5-2) to
set appropriate value for active sequence parameter. Value selected
is shown on the ammeter (see Section 5-4). Also, the ammeter LED for
the corresponding unit of measure
(A, S) of the active parameter will be
illuminated.
See Section 5-16 for all Sequencer
parameter ranges.
1
INITIAL A (Initial Amperage) - Use
control to select a starting amperage that is different from the weld
amperage.
Application:
Initial Amperage can be used while
GTAW welding to assist in preheating cold material prior to depositing
filler material, or to ensure a soft
start.
INITIAL t (Initial Time)(LX Models
Only) - Press control again and turn
Encoder to select amount of time
that is needed at the beginning of
the weld.
INITIAL SLOPE t (Initial Slope
Time) Use control to select amount
of time that it takes to slope up/
down from initial amperage to weld
amperage. To disable, set to 0.
4
Amperage Switch Pad
Weld Time (LX Models Only) Press Amperage switch pad twice.
Set desired length of weld time.
FINAL SLOPE t (Final Slope Time)
- Use control to select amount of
time that it takes to slope up/down
from weld amperage to final amperage. To disable, set to 0.
Application:
Final Slope should be used while
GTAW welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
FINAL A (Final Amperage) - Use
control to select amperage to which
weld amperage has sloped up/
down to.
FINAL t (Final Time)(LX Models
Only) - Press control again and turn
Encoder to select amount of time
that is needed at the end of the
weld.
Return To Table Of Contents
OM-2222 Page 29
5-11. Adjust Controls (Preflow/Post Flow/DIG/Purge)
1
Adjust
Press switch pad until desired function
LED is illuminated.
3
2
3
2
Encoder Control
Ammeter
Turn encoder (see Section 5-2) to set
appropriate value for active Adjust parameter. Value selected is shown on
the ammeter (see Section 5-4). Also,
the ammeter LED for the corresponding unit of measure (S, %) of the active
parameter will be illuminated.
See Section 5-16 for all Adjust parameter ranges.
PREFLOW - If the TIG HF process is
active (see Section 5-7) and Preflow is
shown on the control panel, use control
to set length of time gas flows before
arc initiation. To set Preflow time for
models that do not have Preflow Time
control on the front panel, see Section
5-15.
Application: Preflow is used to purge
the immediate weld area of atmosphere. Preflow also aids in consistent
arc starts.
. Some features
shown are
not available on all models.
1
POST FLOW - If the TIG process is active (see Section 5-7), use control to
set length of time gas flows after welding stops.
Application:
Postflow is required to cool tungsten
and weld, and to prevent contamination of tungsten and weld. Increase
postflow time if tungsten or weld are
dark in appearance.
DIG - If the DC Stick process is active
(see Section 5-7), use control to set
amount of DIG. When set at 0, shortcircuit amperage at low arc voltage is
the same as normal welding amperage.
When setting is increased, short-circuit
amperage at low arc voltage increases.
Application:
Control helps arc starting or making
vertical or overhead welds by increasing amperage at low arc voltage, and
reduces electrode sticking while welding.
PURGE - While in the TIG process
(see Section 5-7), to activate the gas
valve and start the purge function,
push and hold the Adjust switch pad for
the desired amount of purge time. To
set from 1 to 50 seconds of additional
purge time, continue to hold the Adjust
switch pad while turning the encoder
control. Factory default setting is 0.
While Purge is active, (-P-) is shown in
the left display, and purge time is
shown in the right display.
Pressing any front panel switch pad will
end the purge time display, but gas will
continue to flow until the preset time
has timed out.
Application: Purge is used to clear the
shielding gas lines of contaminates.
OM-2222 Page 30
Return To Table Of Contents
5-12. AC Waveshape (Dynasty Models Only)
1
2
3
3
AC Waveshape
Encoder Control
Ammeter
Turn encoder (see Section 5-2) to
set appropriate value for active AC
Waveshape parameter. Value selected is shown on the ammeter
(see Section 5-4).
2
See Section 5-16 for all AC Waveshape parameter ranges.
Balance: AC Balance Control is
enabled only if AC TIG process is
selected. Use control to set percentage of time polarity is electrode
negative.
Application:
When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only
a minimal amount, approximately a
0.10 in (2.5mm) of etched zone
along the weld toes is required.
Joint configuration, set-up, process
variables, and oxide thickness may
affect setting.
1
AC Frequency: AC Frequency
Control is enabled only if AC TIG
process is selected. Use control to
set AC frequency (cycles per second).
Application:
AC frequency controls bead width
and directional control. As AC frequency decreases, weld bead/
puddle gets wider. As AC frequency
increases, weld bead/puddle becomes narrower and the arc becomes more focused. Travel speed
can increase as AC frequency increases.
5-13. Spot Time Control (Reconfigured RMT 2T HOLD Output Selection) (All Models)
1
1
SPO
Spot Time Meter Display
Select Spot function according to
Section 6-2C.
3
Or
2
3
Amperage Switch Pad
Encoder Control
Set spot parameters as follows:
Press Amperage switch pad once
(meter A LED turns on) and turn Encoder to set spot amperage. Press
Amperage switch pad again, (meter
S LED lights) and turn Encoder to
set spot time (.1−25 seconds). Factory default setting is 1 second.
1.0
Application: To provide a timed
weld. Used for tacking, and thin
sheet joining.
Or
Or
2
Return To Table Of Contents
OM-2222 Page 31
5-14. Memory (Program Storage Locations 1-4) (DX And LX Models If Available)
1
2
3
Memory (Program Storage
1-4) Switch Pad
Polarity Switch Pad
Process Switch Pad
To create, change, or recall a
welding parameters program,
proceed as follows:
1
First, press Memory switch pad until
the desired program storage location (1-4) LED is illuminated
Second, press Polarity switch pad
until the desired polarity, AC or DC,
LED is illuminated
1st
Third, press Process switch pad until desired process, TIG HF Impulse,
TIG Lift Arc, or Stick, LED is illuminated.
2
The program at the chosen location,
for the desired polarity and process,
is now the active program.
2nd
3rd
3
Fourth, change or set all desired parameters (see Section 5-16 for parameters).
. Some features
shown are
not available on all models.
TIG (HF or Lift)
AC
And
Stick
Memory Locations
1−4
And
TIG (HF or Lift)
DC
And
Stick
Each memory location (1 thru 4) can store parameters for both
polarities, and each polarity can store parameters for both process (TIG or Stick) for a total of 16 programs.
OM-2222 Page 32
Return To Table Of Contents
5-15. Setting Preflow Time For Use With TIG HF Impulse On Models That Do Not Have A
Preflow Control On The Front Panel
4
SEL 0.2
2
1
And
3
V
Or
Rear Panel
1 Process Control Pad
2 Adjust Control Pad
3 Power Switch
To adjust preflow, turn power switch on, and
then press the Process and Adjust switch
pads before the software version clears the
meters, and hold the switch pads until software version clears the meters.
Upon power up as described, the TIG Impulse, Postflow, DIG, and meter S LED’s
turn on, and the factory default setting [SEL]
[0.2] will be displayed.
Return To Table Of Contents
4 Encoder Control
Turn encoder to select from 0 to 25 seconds
of preflow. The value selected is displayed
on the ammeter.
Application: Preflow is used to purge the
immediate weld area of atmosphere. Preflow also aids in consistent arc starting.
OM-2222 Page 33
5-16. Factory Parameter Defaults And Range And Resolution
Parameter
Default
Range And Resolution
MEMORY
1
1−4
*POLARITY
DC
AC / DC
PROCESS
TIG HF Impulse
TIG HF Impulse / TIG Lift / Stick
**Stick OCV
Low OCV
Low OCV / Normal OCV
OUTPUT
RMT STD
RMT STD / RMT 2T / ON
**RMT 2T
2T
RMT 2T can be reconfigured for: 2T / 4T / Mini Logic
/ 4T Momentary / Spot (see Section 6-2C)
A MAIN / PEAK
*AC TIG
150 A
5 − 300 Amps
*AC STICK
110 A
5 − 300 Amps
DC TIG
150 A
5 − 300 Amps
DC STICK
110 A
5 − 300 Amps
Spot Time
1.0 S
0.1 − 25.0 Seconds
***Weld Time
0S
Dual Range And Resolution
0.0 − 99.9 / 100 − 999 Seconds
PULSER
Off
ON / OFF
PPS
100 Hz
Dual Range And Resolution
0.1 − 9.9 / 10 − 500 Hertz
PEAK t
40%
5 − 95 Percent
BKGND A
25%
5 − 95 Percent
**Display PPP While Pulse Welding
Off
Off / On
INITIAL A
20 A
5 − 300 Amps
***Initial Time
0 S
0.0 − 25.0 Seconds
INITIAL SLOPE t
0S
0.0 − 25.0 Seconds
FINAL SLOPE t
0S
0.0 − 25.0 Seconds
FINAL A
5A
5 − 300 Amps
***Final Time
0S
0.0 − 25.0 Seconds
PREFLOW
0.2 S
0.0 − 25.0 Seconds
POST FLOW
10.0 S
0.0 − 50.0 Seconds @ 0.2 Second Resolution
DIG
30%
0 − 100 Percent
BALANCE
75%
30 − 99 Percent
FREQUENCY
120 Hz
20 − 250 Hertz
SEQUENCER
ADJUST
*AC WAVESHAPE
OM-2222 Page 34
Return To Table Of Contents
**Impulse HF Start parameters for each program (1-4)
MAXSTAR:
Amperage
30 A
5 − 200 Amps
Time
3 mS
1 − 200 Milliseconds
Polarity
EN
EP / EN
Amperage
30 A
5 − 200 Amps
Time
3 mS
1 − 200 Milliseconds
EP
EP / EN
40 A
5 − 200 Amps
40 mS
1 − 200 Milliseconds
*DYNASTY:
DC:
AC:
Polarity
Amperage
Time
* DYNASTY parameter selection only
** Parameter adjusted using a power up configuration only
*** Parameter used with the automation option (LX models only)
5-17. Resetting Unit To Factory Default Settings (All Models)
1
2
3
4
Process Switch Pad
Output Switch Pad
Adjust Switch Pad
Power Switch
To reset all welding power source
functions to original factory settings,
lockout feature must be off (see Section 6-4). Next turn power on, then
press the Process, Output, and Adjust switch pads before the software
version clears the meters, and hold
the switch pads until software version clears the meters.
1
2
3
4
V
Or
Rear Panel
Return To Table Of Contents
OM-2222 Page 35
SECTION 6 − ADVANCED FUNCTIONS
6-1. Programable TIG Start Parameters
A.
Accessing Programmable TIG Start Parameters
4
2
Or
5
1
6
Or
3
And
V
Or
Rear Panel
NOTE: The welding cycle can be executed while in programmable start mode.
Before accessing programmable TIG
Start Polarity, Amperage, and Time
modes, be sure that all procedures and
parameters are established.
1 Process Switch Pad
2 Amperage Switch Pad
3 Power Switch
To access the programmable TIG Start
Amperage and Time screens, turn power
on, and then press the Process and Amperage switch pads before the software
version clears the meters. Hold switch
OM-2222 Page 36
pads until software version clears the
meters and [SEL] [EP] or [SEL] [EN] appears.
Press Memory switch pad to select desired memory location (see Section
5-14).
Press the Process switch pad to select
the desired process, TIG HF Impulse or
TIG Lift Arc, for your application (see
Section 5-7). The parameter values are
the same for both processes, and any
changes made to the values in one process, are duplicated in the other process.
5
6
4
Memory Switch Pad (If Equipped)
Polarity Switch Pad (If Equipped)
Press Polarity switch pad to select AC or
DC (see Section 5-6).
Note: Each memory location and each
polarity (AC or DC) has its own set of start
parameters.
Return To Table Of Contents
Output Switch Pad
Press Output switch pad to select desired type of control (see Section 5-8).
Proceed to Section B, C and/or D.
To save changes and exit Advanced
Functions, turn power off.
B.
Changing Programmable TIG Start Polarity (Dynasty Models Only)
3
SEL
2
E−
Or
Or
1
C.
1
Amperage Switch Pad
2
Encoder Control
3
Amps Meter
To adjust TIG Start Polarity proceed as
follows:
Press Amperage switch pad. Switch pad
LED turns on, and meter % LED turns on.
The current Start Polarity, (SEL] [E−] or [SEL]
[EP] is displayed on meters, and can be
adjusted (see Section 5-16) by turning
the Encoder control.
To change Start Amperage, proceed to
Section C.
Changing Programmable TIG Start Amperage (All Models)
3
SEL
2
20
Or
Or
1
1
Amperage Switch Pad
2
Encoder Control
3
Amps Meter
To adjust TIG Start Amperage proceed
as follows:
Press Amperage switch pad. Switch pad
LED turns on, and meter A LED turns on.
The current Start Amperage is displayed
Return To Table Of Contents
on the amps meter, and can be adjusted
(see Section 5-16) by turning the
Encoder control.
To change Start Time, proceed to Section
D.
OM-2222 Page 37
D. Changing Programmable Start Time (All Models)
3
SEL
2
10
Or
Or
1
1
Amperage Switch Pad
2
Encoder Control
3
Amps Meter
OM-2222 Page 38
To adjust Programmable Start Time proceed as follows:
Press Amperage switch pad, and meter
S LED turns on. The current Start Time is
Return To Table Of Contents
displayed on the amps meter, and can be
adjusted by turning the Encoder control
(see Section 5-16).
6-2. Output Control And Trigger Functions
A. Remote (Standard) Torch Trigger Operation
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P&H
R
R
Maintained Switch
Foot Or Finger
Remote Control
P&H = Push trigger and hold
R = Release trigger.
NOTE: When a foot or finger remote current control is connected to the welding power source, initial amps, initial slope, final slope
and final amps are controlled by the remote control, not by the welding power source.
B. Remote 2T Torch Trigger Operation
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P&R
P&R
P&R = Push trigger and release. NOTE: If torch trigger is held more than 3 seconds, operation reverts to RMT STD (Remote Standard) mode.
Return To Table Of Contents
OM-2222 Page 39
C. Reconfiguring RMT 2T HOLD For 2T, Spot, 4T, 4T Momentary, Or Mini Logic Control
4
SEL
H−2
Or
Or
1
2
3
And
V
Or
Rear Panel
For RMT STD (Remote Standard), RMT
2T Hold (Remote 2T Hold), and On trigger operation, see Section 6-2A, B, and
H.
1
Process Switch Pad
2
Output Switch Pad
3
Power Switch
OM-2222 Page 40
To access the RMT 2T HOLD reconfiguration screen, turn power switch on
and then press the Process and Output
switch pads before the software version
clears the meters. Hold the switch pads
until software version clears the meters
and [SEL] [H-2], [SEL] [SPO], [SEL] [H-4], [SEL]
[H4L], or[SEL] [H4E] appears.
4 Encoder Control
Turn Encoder to change functions. Active function will be displayed on amperage (right) meter.
Return To Table Of Contents
5
Meter Displays
Meter displays for the different functions
will be as shown.
Press torch trigger or turn power Off to
save setting.
NOTE: After 2T has been reconfigured
and one of the reconfigured functions is
selected during normal operation, H−4,
H4L, H4E or SPO will be displayed for 1 second as a reminder to the operator.
SEL
SEL
H−2
=
2T (See Section 6-2B
for operation)
= Spot (See Section 6-2G
SPO
for operation)
5
SEL
H−4
SEL
H4L
SEL
H4E
= 4T (DX, LX and CE Models)
(See Section 6-2D
for operation)
=
Mini Logic (DX, LX and
CE Models)
(See Section 6-2E
for operation)
= 4T Momentary
(DX, LX and CE Models)
(See Section 6-2F
for operation)
Return To Table Of Contents
OM-2222 Page 41
D. 4T Specific Trigger Method (DX, LX And All CE Models)
1
1
4T (Specific Trigger
Operation)
Sequencer is required to reconfigure for 4T.
SEL
Select 4T according to Section
6-2C.
H−4
Torch trigger operation is as shown.
= 4T
4T allows the operator to toggle between weld current and final current
without breaking the arc.
NOTE: When a remote switch is
connected to the welding power
source, use the remote switch to
control the weld cycle. Amperage is
controlled by the welding power
source.
Application:
Use 4T trigger method when the
functions of a remote current control are desired, but only a remote
on/off control is available.
Current (A)
Torch Trigger Operation
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
P&H
R
P&R
P&R
P&H = Push and hold trigger
R = Release trigger
P&R = Push trigger and release in less than 3/4 seconds
OM-2222 Page 42
Return To Table Of Contents
P&H
R
E. Mini Logic Operation (DX, LX And All CE Models)
1
1
Mini Logic Meter Display
Select Mini Logic according to Section 6-2C.
Torch trigger operation is as shown.
SEL
H4L
=
While in mini logic, the operator
may use the trigger on the remote
device to toggle between initial
slope or main amps and initial amps
as illustrated.
Mini Logic
During Mini Logic, Final Amperage
is not available. Final slope will always slope to minimum amperage
and end the cycle.
NOTE: When a remote switch is
connected to the welding power
source, use the remote switch to
control the weld cycle. Amperage is
controlled by the welding power
source.
Application: This ability to change
current levels without either initial
slope or final slope, gives the operator the opportunity to adjust filler
metal without breaking the arc.
Torch Trigger Operation
Main Amps
Final Slope
Initial Slope
*
Initial Amps
*
*
*
Postflow
Preflow
P&H
R
P&R
P&R
P&R
P&R
P&R
P&H
P&H = Push and hold trigger
R = Release trigger
P&R = Push trigger and release in less than 3/4 seconds
* = Arc can be extinguished at final slope rate at any time by pushing and holding trigger.
Return To Table Of Contents
OM-2222 Page 43
F. 4T Momentary Operation (DX, LX And All CE Models)
1
4T Momentary Meter
Display
Select 4T Momentary according
to Section 6-2C.
4T Momentary torch trigger operation is as shown.
1
SEL
H4E
=
NOTE: When a remote switch is
connected to the welding power
source, use the remote switch to
control the weld cycle. Amperage is controlled by the welding
power source.
4T Momentary Main
Application:
Use 4T Momentary trigger method when the functions of a remote current control are desired,
but only a remote on/off control is
available.
Current (A)
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
*
Postflow
Preflow
P&R
P&R
P&R
P&R
P&R = Push and release trigger.
* = Push and releasing during final slope will break the arc and go to postflow.
NOTE: For first torch trigger push & release, if trigger is held more than 3 seconds, trigger cycle ends
OM-2222 Page 44
Return To Table Of Contents
P&R
G. Spot Control Operation
1
1
SEL
Spot Function Meter Display
Select Spot function according to
Section 6-2C.
NOTE: While in Spot Control, Sequencer settings will be ignored
and will not be programmable.
SPO
=
Spot
NOTE: When a remote switch is
connected to the welding power
source, use the remote switch to
control the weld cycle. Amperage is
controlled by the welding power
source.
Torch trigger operation is as shown.
Application: To provide a timed
weld. Used for tacking, and thin
sheet joining.
Current (A)
Timed Spot Weld Amps
Postflow
Preflow
Push & Hold
Trigger
Release Trigger After
Spot Time Is Done
Return To Table Of Contents
OM-2222 Page 45
H. On Trigger Operation
Voltage (V)
ON
2 Sec
Current (A)
Stick
Touch Stick
Electrode
Lift Stick
Electrode
Current (A)
Lift
Main Amperage
Initial Amperage
Initial Slope
Touch Current
Touch Tungsten
Lift Tungsten
Slightly
OM-2222 Page 46
Lift Tungsten
Return To Table Of Contents
6-3. Arc Timer/Counter Display
3/4
123
456
Or
Or
Or
1
2
1
And
V
Or
Rear Panel
1
2
Output And Amperage Controls
Power Switch
To display the arc timer/counter, turn power switch on, and then press the Amperage Control and Output switch pads before the software version clears the meters, and hold the switch pads until software version clears the meters
3 Arc Timer Display
Upon power up as described above, the
meter S LED will turn on, and arc time will
be displayed for 5 seconds as [000 000 ] to
[999 959 ]. The first four numbers indicate
hours, and the last two numbers indicate
minutes. Arc time shown in example is
read as 1,234 hours and 56 minutes. Maximum arc time is 9,999 hours and 59 minutes.
Return To Table Of Contents
4
Arc Counter
After 5 seconds, the meter A LED turns
on, and the arc counter will be displayed
for the next 5 seconds as [000 000 ] to [999
999 ]. The maximum arc cycle count is 999
999.
OM-2222 Page 47
6-4. Lockout Functions
A. Accessing Lockout Capability
4
5
LL−0
−−
000
1
6
And
000
LL−0
L1
or 2,3,4
3
2
V
Or
Rear Panel
See Section 5-1 for explanation of controls referred to in all of
Section 6-4.
Toggle Amperage (A) switch pad to light the meter S LED. You may
now select a lockout level.
There are four (1−4) different lockout levels. Each successive level
allows the operator more flexibility.
There are four lockout levels available. Turn Encoder control to select a lockout level (see Sections B for lockout level descriptions).
NOTE: Before activating lockout levels, be sure that all procedures
and parameters are established. Parameter adjustment is limited
while lockout levels are active.
6
1
2
3
Amperage (A) Switch Pad
Adjust Switch Pad
Power Switch
NOTE: Setting a three digit lockout number of [000], or setting a lockout level of [L−−] will cause a lockout off condition.
To access lockout screens, turn On power switch, and then before
the software version clears the meters, push and hold the Amperage
and Adjust switch pads until software version number clears meters.
4
Lockout Off
Upon power up as described, the meter % and Amperage (A) switch
pad LED’s light, and the meter display will be as shown for a lockout
off condition.
5
Encoder Control
To turn On the lockout feature, proceed as follows:
Pressing Amperage (A) switch pad will toggle between the meter %
and S LED’s. Toggle switch pad until % LED is on.
Turn Encoder control to select a three digit lockout number. Number
will appear on the voltage (left) meter. Select any number from [001]
thru [999 ]. IMPORTANT: remember this three digit number, as you
will need it to turn the lockout feature off.
OM-2222 Page 48
Lockout On
Once the desired three digits have been entered and a lockout level
selected, press torch trigger or turn Off power to complete lockout on
sequence.
To turn Off the lockout feature, proceed as follows:
To access lockout screens, turn On power switch, and then before
the software version clears the meters push and hold the Amperage
and Adjust switch pads until software version number clears meters.
Upon power up as described, the meter % and Amperage (A) switch
pad LED’s will turn on, and the meter display will be as shown for a
lockout on (see callout 6) condition.
Use Encoder control to enter the same three digits that were used
to turn on the lockout feature.
Press the Amperage (A) switch pad. The meter % LED will turn off,
and the S LED will light. The amperage (right) meter display will
change to [L−−]. The lockout feature is now off.
Press torch trigger or turn Off power to complete lock out Off
sequence.
Return To Table Of Contents
B. LockOut Levels
Level 1
NOTE: Before activating lock out
levels, be sure that all procedures
and parameters are established.
Parameter adjustment is limited
while lock out levels are active.
Level 1
NOTE: Remote amperage control
is not available in level 1.
TIG Output Selection
Use Output Switch Pad To
Select A Trigger Method
For The TIG Process
If either the TIG HF Impulse or TIG
Lift Arc process (see Section 5-7)
was active when lockout level 1
was activated, the operator can
choose between RMT STD (Remote Standard) or RMT 2T HOLD
(Remote 2T Hold). The On function
is also available if TIG Lift Arc was
active.
If RMT 2T HOLD was reconfigured
(see Section 6-2C) prior to lockout
level 1 activation, the reconfigured
output mode (4T, 4T momentary,
mini logic, or spot) is available to
the operator instead of RMT 2T.
Stick Output Selection
If the Stick process was active
when lockout level 1 was activated,
the operator can choose between
RMT STD or On.
When parameter change or selection is limited by lock level 1, [L-1 ] is
displayed as a reminder.
Level 2
NOTE: Remote amperage control
is not available in level 2.
Includes all the functions of level 1
plus Polarity and Process Selection
(see Sections 5-6 and 5-7).
Use Output Switch Pad To
When parameter change or selection is limited by lock level 2, [L-2] is
displayed as a reminder.
Select A Trigger Method
For The Stick Process
Level 2
Select Process
Process Selection
Return To Table Of Contents
OM-2222 Page 49
B. Lock Out Levels (Continued)
Level 3
Level 3
NOTE: Remote amperage control is
not available in level 3.
Use Encoder Control To
Adjust Amperage +/− 10%
Of Preset Value.
Includes all the functions of levels 1
and 2 plus the following:
+/− 10% adjustment of preset TIG
or Stick Weld Amps
Select desired process, TIG or
Stick, and use Encoder control to
adjust amperage +/− 10% of preset
amperage value, up to the limits of
the machine. If operator tries to go
beyond the +/− 10%, the amperage
(right) meter will display [L-3 ] as a reminder.
Pulser ON/Off Control
Gives operator the ability to turn on/
off the Pulser control.
Select Process
+/− 10 % Amperage Adjust Control
When parameter change or selection is limited by lock level 3, [L-3] is
displayed as a reminder.
Level 4
Includes all the functions of levels 1,
2, and 3 plus the following:
Remote Amperage Control
Allows operator to use remote amperage control if desired. Remote
control operates from minimum to
maximum of preset amperage value. Connect remote control device
according to Section 4-7.
When parameter change or selection is limited by lock level 4, [L-4] is
displayed as a reminder.
Turn Pulser Control On/Off
Pulser On/Off Control
Remote Amperage Control
Level 4
A
B
K
J
I
H
C L N
D M
G
E F
OM-2222 Page 50
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6-5. Setting Unit To Display PPP While Pulse Welding (DX And LX Models Only)
5
PPP
4
sel
−−−
2
1
3
And
V
Or
Rear Panel
1
Output Switch Pad
2
Pulser Switch Pad
3
Power Switch
To access the PPP while welding display, turn power switch on, and then
press the Output and Pulser switch
pads before the software version
clears the meters. Hold the switch pads
until [SEL] [−−−] or [SEL] [PPP] appears.
4 Encoder Control
5 PPP Meter Display
Turn Encoder to change between standard and (PPP) meter display.
When the (PPP) meter display feature is
active while pulse welding, the (PPP) will
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be displayed on the right meter display,
and the Meter Hold feature is disabled.
The (PPP) meter display feature will not
effect the normal amperage display or
Meter Hold capabilities when in a nonpulse welding mode.
Press torch trigger or turn off power to
save setting and end this set-up.
OM-2222 Page 51
6-6. Stick Open-Circuit Voltage (OCV) Selection (All Models)
5
6
sel
lO1
3
2
1
4
And
V
Or
Rear Panel
1 Process Switch Pad
2 Adjust Switch Pad
3 Amperage Switch Pad
4 Power Switch
To access the Stick OCV selection,
turn power switch on and then press
the Process, Adjust and Amperage
switch pads before the software version clears the meters. Hold the switch
OM-2222 Page 52
pads until [SEL] [LO1] or [SEL] [LO0) appears.
5
Encoder Control
6
Meter Display
Turn Encoder to change between low
OCV [SEL] [LO1] and normal OCV [SEL]
[LO0]. Active selection is displayed on
the meters.
Return To Table Of Contents
When Stick low OCV is selected, opencircuit voltage is between 9 and 14
volts. When Stick normal OCV is selected, open-circuit voltage is approximately 95 volts.
Application: For most Stick applications use low open-circuit voltage. Use
normal open-circuit voltage for hard to
start Stick electrodes, or if required for
your particular application.
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING
7-1. Routine Maintenance
Y Disconnect power before maintaining.
. Maintain more often during severe conditions.
3 Months
Replace
unreadable
labels.
Clean and tighten
weld terminals.
Replace Damaged
Gas Hose
3 Months
Repair Or Replace
Cracked Cables
And Cords
6 Months
Y Do not remove case when
blowing out inside of unit
(see Section 7-2) .
Blow out inside. During
heavy service clean
monthly.
7-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
ST-802 137-A
Return To Table Of Contents
OM-2222 Page 53
7-3. Voltmeter/Ammeter Help Displays
0
3
6
9
12
V
A
HE.L
P−0
V
A
HE.L
P−3
V
A
HE.L
P−6
V
A
HE.L
P−9
V
A
HE.L
P13
. All directions are in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
0 Help 0 Display
Indicates a short in the thermal protection
circuitry located on the left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
1 Help 1 Display
Indicates a malfunction in the primary power circuit caused by an overcurrent condition in the primary IGBT switching circuit.
Contact a Factory Authorized Service
Agent if this display is shown.
2 Help 2 Display
Indicates an open in the thermal protection
circuitry located on the left side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
3 Help 3 Display
Indicates the left side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-3). Operation
will continue when the unit has cooled.
OM-2222 Page 54
V
1
4
7
10
A
HE.L
P−1
V
A
HE.L
P−4
V
A
HE.L
P−7
V
A
HE.L
P10
4 Help 4 Display
Indicates an open in the thermal protection
circuitry located on the right side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
5 Help 5 Display
Indicates the right side of the unit has overheated. The unit has shut down to allow the
fan to cool it (see Section 4-3). Operation
will continue when the unit has cooled.
6 Help 6 Display
Indicates that the input voltage is too low
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (±10%). Have an
electrician check the input voltage if this
display is shown. Can also be displayed if
the board power supply is being shorted.
7 Help 7 Display
Indicates that the input voltage is too high
and the unit has automatically shut down.
Operation will continue when the voltage is
within the operating range (±10%). Have an
electrician check the input voltage if this
Return To Table Of Contents
2
5
8
11
V
A
HE.L
P−2
V
A
HE.L
P−5
V
A
HE.L
P−8
V
A
HE.L
P12
display is shown. Can also be displayed if
the board power supply is being shorted.
8 Help 8 Display
Indicates a malfunction in the secondary
power circuit of the unit caused by a high
open circuit condition. Contact a Factory
Authorized Service Agent if this display is
shown.
9 Help 9 Display
Indicates a short in the thermal protection
circuitry located on the right side of the unit.
Contact a Factory Authorized Service
Agent if this display is shown.
10 Help 10 Display
Indicates torch trigger is depressed. Release trigger to continue.
11 Help 12 Display
Indicates a non-allowable set-up on the
front panel.
12 Help 13 Display
Command signal broken causing weld output to stop, but gas continues to flow.
7-4. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-15).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-15).
Check for proper input power connections (see Section 4-15).
No weld output; meter display On.
If using remote control, be sure correct process is enabled to provide output control at Remote 14
receptacle (see Section 4-7 as applicable).
Input voltage outside acceptable range of variation (see Section 4-14).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-3).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-6).
Clean and tighten all weld connections (see Section 4-6).
No 115 volts ac output at duplex receptacle.
Reset circuit breaker CB1 (see Section 4-5).
Fan not operating.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Wandering arc
Use proper size tungsten (see Section 10).
Use properly prepared tungsten (see Section 10).
Reduce gas flow rate (see Section 4-11).
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Increase postflow time (see Section 5-11).
Check and tighten all gas fittings (see Section 4-11).
Water in torch. Refer to torch manual.
Return To Table Of Contents
OM-2222 Page 55
SECTION 8 − ELECTRICAL DIAGRAMS
Figure 8-1. Circuit Diagram
OM-2222 Page 56
Return To Table Of Contents
200 325-F
Return To Table Of Contents
OM-2222 Page 57
SECTION 9 − HIGH FREQUENCY
9-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG
high_freq 12/96 − S-0693
9-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
5
6
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
OM-2222 Page 58
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9-3. Correct Installation
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
9
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground
conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Metal Building Requirements
9
Metal Building Panel Bonding Methods
Bolt or weld building panels together, install
copper straps or braided wire across seams,
and ground frame.
Ground water pipes every 50 ft (15 m).
10 Windows and Doorways
7
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
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11 Overhead Door Track
Ground the track.
OM-2222 Page 59
SECTION 10 − 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.
10-1. Selecting Tungsten Electrode
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
DC − Argon − Electrode Negative/Straight
Polarity
DC − Argon − Electrode Positive/Reverse
Polarity
.010”
Up to 25
*
.020”
15-40
*
2% Thorium Alloyed Tungsten (Red
Band)
.040”
25-85
*
1/16”
50-160
10-20
3/32”
135-235
15-30
1/8”
250-400
25-40
5/32”
400-500
40-55
3/16”
500-750
55-80
1/4”
750-1000
80-125
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour) − 7 to 16.5 lpm (liters per minute).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
10-2. Safety Information About Tungsten
Y Grinding the tungsten electrode produces dust and flying sparks which can cause
injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using tungsten
containing ceria, lanthana,
or yttria instead of thoria.
Grinding dust from thoriated
electrodes contains low-level radioactive material.
Properly dispose of grinder
dust in an environmentally
safe way. Wear proper face,
hand, and body protection.
Keep flammables away.
1
2
1
2
Tungsten Electrode With
Balled End
Pointed Tungsten Electrode
Ref. S-0161
OM-2222 Page 60
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10-3. 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
1
2
Diameter of this flat determines
amperage capacity.
3
3
Stable Arc
Flat
Grinding Wheel
Grinding wheel should be dedicated to grinding tungsten only.
4
Straight Ground
1
1
2
3
Arc Wander
Point
Grinding Wheel
2
Grinding wheel should be dedicated to grinding tungsten only.
4
Ideal Tungsten Preparation − Stable Arc
4
Radial Ground
3
4
Wrong Tungsten Preparation − Wandering Arc
Ref. S-0161 / Ref. S-0162
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OM-2222 Page 61
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW)
11-1. Typical DC - GTAW 16 Gauge Stainless Steel Set-Up
Ammeter
Encoder
198 719
This symbol indicates which functions should be active for stainless steel.
• Turn power on (switch located on rear panel)
•
Press Process switch pad until TIG HF Impulse LED is lit
•
Press Output switch pad until RMT STD LED is lit
•
Press Adjust switch pad until Post Flow LED is lit
•
Turn Encoder control to set 8 seconds of Post Flow time
•
Press Amperage A switch pad until LED is lit
•
Turn Encoder control to set desired amperage (50 - 80 amps).
. The ammeter displays the parameter for any of the following units of measure when they are active:
amperage, time, percentage, or frequency. The corresponding LED, located directly below the ammeter, will also light up. The ammeter also displays actual amperage while welding.
OM-2222 Page 62
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11-2. Positioning The Torch
3
2
4
90°
1
Y Grinding the tungsten electrode produces dust and flying sparks which can cause
injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using cerium or
lanthanum based tungsten
instead of thoriated. Thorium dust contains low-level
radioactive material. Properly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
1
Workpiece
Make sure workpiece is clean
before welding.
2
Work Clamp
Place as close to the weld as
possible.
10−15°
3
4
5
6
4
5
6
10−25°
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten
according to Sections 10-1 and
10-3.
Guidelines:
5
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.
6
1/16 in
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
3/16 in
The tungsten extension should be
no greater than the inside diameter
of the gas cup.
Bottom View Of Gas Cup
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
Return To Table Of Contents
OM-2222 Page 63
11-3. Lift-Arc And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
Lift-Arc Start Method
1
“Touch”
2
1−2
Seconds
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control.
Hold electrode to workpiece for
1-2 seconds, and slowly lift electrode. Arc is formed when electrode
is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting
contaminated.
Application:
Do NOT Strike Like A Match!
Lift-Arc is used for the DCEN or AC
GTAW process when HF Start
method is not permitted, or to replace the scratch method.
HF Start
When HF Start button light is On,
start arc as follows:
High frequency turns on to help
start arc when output is enabled.
High frequency turns off when arc is
started, and turns on whenever arc
is broken to help restart arc.
Application:
HF start is used for the DCEN
GTAW process when a non-contact arc starting method is required.
OM-2222 Page 64
Return To Table Of Contents
11-4. 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
Return To Table Of Contents
OM-2222 Page 65
11-5. 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-2222 Page 66
Return To Table Of Contents
SECTION 12 − STICK WELDING (SMAW) GUIDELINES
12-1. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
1
1
Front Panel
Correct front panel display for basic
Stick DCEP welding.
. For all front panel switch pad
controls: press switch pad to
turn on light and enable
function.
NOTE: Gray on nameplate indicates a Stick function (see Section
5-1 for description of controls).
ST-198 719
Return To Table Of Contents
OM-2222 Page 67
7014
7018
7024
Ni-Cl
308L
OM-2222 Page 68
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
LOW
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
PENETRATION
EP
6011
AC
6010
DC*
450
400
350
300
AMPERAGE
RANGE
250
200
150
POSITION
6013
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
ELECTRODE
6010
&
6011
100
50
DIAMETER
ELECTRODE
12-2. Electrode and Amperage Selection Chart
MIN. PREP, ROUGH
HIGH SPATTER
LOW
SMOOTH, EASY,
FASTER
LOW
CAST IRON
LOW
STAINLESS
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
Return To Table Of Contents
12-3. Stick Welding Procedure
Y Weld current starts when
electrode touches workpiece.
5
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.
4
2
1
Workpiece
Make sure workpiece is clean before welding.
2
3
3
A small diameter electrode requires
less current than a large one. Follow electrode manufacturer’s
instructions when setting weld amperage (see Section 12-2).
6
1
Work Clamp
Electrode
7
4
5
6
Insulated Electrode Holder
Electrode Holder Position
Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.
Tools Needed:
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove slag
and check weld bead before making another weld pass.
stick 12/96 − ST-151 593
12-4. Striking an Arc − Scratch Start Technique
1
1
2
3
Electrode
Workpiece
Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted too
high. If electrode sticks to workpiece, use a quick twist to free it.
2
3
S-0049
12-5. Striking an Arc − Tapping Technique
1
1
2
3
2
Electrode
Workpiece
Arc
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
3
S-0050
Return To Table Of Contents
OM-2222 Page 69
12-6. Positioning Electrode Holder
10°-30°
90°
90°
End View of Work Angle
Side View of Electrode Angle
GROOVE WELDS
10°-30°
45°
45°
End View of Work Angle
Side View of Electrode Angle
FILLET WELDS
S-0060
12-7. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
1
2
4
3
5
S-0053-A
12-8. Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
4
5
1
2
3
4
No Overlap
Good Penetration into Base
Metal
5
S-0052-B
OM-2222 Page 70
Return To Table Of Contents
12-9. Conditions That Affect Weld Bead Shape
NOTE
Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.
Angle Too Small
Correct Angle
10° - 30°
Angle Too Large
Drag
ELECTRODE ANGLE
Spatter
Normal
Too Short
Too Long
ARC LENGTH
Normal
Slow
Fast
TRAVEL SPEED
S-0061
12-10. Electrode Movement During Welding
NOTE
Normally, a single stringer bead is satisfactory for most narrow groove weld joints;
however, for wide groove weld joints or bridging across gaps, a weave bead or
multiple stringer beads work better.
1
2
1
2
3
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side to Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.
3
S-0054-A
Return To Table Of Contents
OM-2222 Page 71
12-11. Butt Joints
1
1
2
Tack Welds
Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position before final weld.
2
Square Groove Weld
Good for materials up to 3/16 in (5
mm) thick.
3
1/16 in
(1.6 mm)
30°
Single V-Groove Weld
Good for materials 3/16 − 3/8 in (5-9
mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment.
Remove scale from material after
cutting. A grinder can also be used
to prepare bevels.
4
3
Create 30 degree angle of bevel on
materials in V-groove welding.
4
Double V-Groove Weld
Good for materials thicker than 3/8
in (9 mm).
S-0662
12-12. Lap Joint
30°
Or Less
30°
Or Less
1
1
1
2
Move electrode in circular motion.
3
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
3
2
Electrode
Single-Layer Fillet Weld
Multi-Layer Fillet Weld
S-0063 / S-0064
12-13. Tee Joint
1
2
Keep arc short and move at definite
rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.
1
2
45°
Or Less
Electrode
Fillet Weld
For maximum strength weld both
sides of upright section.
2
3
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
12-10. Remove slag before making
another weld pass.
1
3
S-0060 / S-0058-A / S-0061
OM-2222 Page 72
Return To Table Of Contents
12-14. Weld Test
1
2
3
3
Strike weld joint in direction shown.
A good weld bends over but does
not break.
3
2 To 3 in
(51-76 mm)
1/4 in
(6.4 mm)
Vise
Weld Joint
Hammer
2 To 3 in
(51-76 mm)
2
2
1
1
S-0057-B
12-15. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas
pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
12-16. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles
that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
Return To Table Of Contents
OM-2222 Page 73
12-17. Troubleshooting − Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
12-18. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow fusion between weld metal and
base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
12-19. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal and
hanging underneath weld.
Excessive Penetration
Possible Causes
Excessive heat input.
Good Penetration
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
OM-2222 Page 74
Return To Table Of Contents
12-20. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metal resulting
in holes where no metal remains.
Possible Causes
Excessive heat input.
Corrective Actions
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
12-21. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
Possible Causes
Unsteady hand.
Corrective Actions
Use two hands. Practice technique.
12-22. Troubleshooting − Distortion
Distortion − contraction of weld metal during welding that forces base
metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
Return To Table Of Contents
OM-2222 Page 75
SECTION 13 − PARTS LIST
. Hardware is common and
not available unless listed.
Figure 13-1. Main Assembly
OM-2222 Page 76
Return To Table Of Contents
ST-802 005-H
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
Figure 13-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 206 108 . .
. . . 3 . . . . . . . . . . . . . 138 442 . .
. . . 3 . . . . . . . . . . . . . 179 309 . .
. . . 4 . . . . . . . . . . . . +175 148 . .
. . . . . . . . . . . . . . . . . . . 175 256 . .
. . . 5 . . . . . . . . . . . . . 134 327 . .
. . . 5 . . . . . . . . . . . . . 179 310 . .
. . . 6 . . . . T2 . . . . ♦193 311 . .
. . . 6 . . . . T2 . . . . ♦193 310 . .
. . . . . . . . RC10 . . . . 166 679 . .
. . . 7 . . . . . . . . . . . . ♦187 461 . .
. . . 8 . . . PC1 . . . . . . 211 245 . .
. . . 8 . . . PC1 . . . . . . 211 248 . .
. . . . . . . . PLG2 . . . . . 115 091 . .
. . . . . . . . PLG3 . . . . . 115 092 . .
. . . . . . . . PLG4 . . . . 131 054 . .
. . . . . . . . PLG5 . . . . . 115 091 . .
. . . . . . . . PLG7 . . . . 130 203 . .
. . . . . . . . PLG8 . . . . . 115 092 . .
. . . . . . . . PLG9 . . . . 131 204 . .
. . . . . . . . PLG10 . . . . 115 094 . .
. . . 9 . . . . T2 . . . . . 180 873 . .
. . . 9 . . . . T2 . . . . . 189 536 . .
. . . . . . . . PLG10 . . . 166 680 . .
. . . 10 . . . GS1 . . . . . 216 607 . .
. . . 11 . . . . . . . . . . . . ♦189 033 . .
. . . 12 . . . CB1 . . . . ♦161 078 . .
. . . 13 . . . . . . . . . . . . . 137 761 . .
. . . 14 . . . . . . . . . . . . . 188 570 . .
. . . 15 . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . ♦175 282
. . . 17 . . . . . . . . . . . . . 175 138
. . . 18 . . . . . . . . . . . . . 182 561
. . . 19 . . . . . . . . . . . . . 201 155
. . . 20 . . . . . . . . . . . . . 198 245
. . . 21 . . . . . . . . . . . . . 176 226
. . . 22 . . . . S1 . . . . . 128 756
. . . 23 . . . PC2 . . . . . 213 198
. . . . . . . . . . . . . . . . . . . 176 879
. . . . . . . . PLG13 . . . 131 204
. . . . . . PLG14, 29 . . . 115 093
. . . . . . . . . . . . . . . . . . . 179 626
. . . 24 . . . . . . . . . . . . +208 471
. . . 25 . . . . . . . . . . . . . 173 693
. . . 26 . . . . . . . . . . . . . 176 736
. . . 27 . . . PC3 . . . . . 210 892
. . . 27 . . . PC3 . . . . . 210 899
. . . . . . . . DD1-6 . . . . 186 914
. . . . . . . . PLG11 . . . . . 115 091
. . . . . . PLG17, 18 . . 131 054
. . . 28 . . . FM . . . . . 175 084
. . . . . . . . . . . . . . . . . . . 135 635
. . . 29 . . . . . . . . . . . . . 200 320
. . . 30 . . . . . . . . . . . . ♦191 172
. . . 30 . . . . . . . . . . . . . 191 173
HANDLE, rubberized carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
LABEL, caution falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LABEL, caution falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
INSULATOR, side RH & LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . 2
LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
BRACKET, mtg aux transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CIRCUIT CARD ASSEMBLY, control . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
VALVE, 24VDC 2way custom port 1/8 orf w/frict . . . . . . . . . . . . . . 1 . . . . . 1
RECEPTACLE, str dx grd 2P 3W 15A . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CIRCUIT BREAKER, 1P 7A 250VAC . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
NUT, 750npt 1.31hex .27h nyl blk . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
PLATE, identification rear
(order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . COVER, receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . BOX, louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . CABLE, pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . BUSHING, strain relief .450/.709 ID . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . NUT, stl locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . SWITCH, tgl 3PST 40A 600VAC (Power Switch) . . . . . . . . . . . . . 1 . . . . . 1
. . KIT, interconnecting replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . SCREW, M5−.8−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . 18
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . BUS BAR, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . FOOT, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4
. . SCREW, mtg foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . 4
. . CIRCUIT CARD, front panel (consisting of) . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . CIRCUIT CARD, front panel (LX Models) (consisting of) . . . . . . . 1 . . . . . 1
. . . . LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . 6
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . 2
. . MOTOR, fan 24VDC 3000RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
. . PLATE, ident front right (10-pin installed) . . . . . . . . . . . . . . . . . . . . 1
. . PLATE, ident front right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
Return To Table Of Contents
OM-2222 Page 77
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
Figure 13-1. Main Assembly (Continued)
. . . 31 . . . RC2 . . . . . 197 181
. . . . . . . . . . . . . . . . . . . 146 212
. . . . . . . . . . . . . . . . . . . 073 332
. . . 31 . . . RC2 . . . . ♦191 302
. . . 32 . . . RC1 . . . . . 191 303
. . . 33 . . . . . . . . . . . . . 192 019
. . . 34 . . . . . . . . . . . . . 202 553
. . . 35 . . . . . . . . . . . . . 202 551
. . . 35 . . . . . . . . . . . . . 202 552
. . . 36 . . . C7,8 . . . . 186 543
. . . 37 . . . . . . . . . . . . . 198 718
. . . 37 . . . . . . . . . . . . . 198 722
. . . 37 . . . . . . . . . . . . . 198 725
. . . 37 . . . . . . . . . . . . . 198 727
. . . 38 . . . . . . . . . . . . . 174 991
. . . 39 . . . . . . . . . . . . . Fig 13-2
. . . 40 . . . . T4 . . . . . 182 108
. . . 42 . . . . . . . . . . . . . 148 329
. . . 43 . . . . . . . . . . . . . 182 826
. . . 44 . . . . . . . . . . . . ♦059 266
. . . 46 . . . . . . . . . . . . . 089 120
. . . 47 . . . . . . . . . . . . . 188 048
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
CONNECTOR & SOCKETS 10-pin (LX Models) . . . . . . . . . . . . . . 1 . . . . .
CONN, circ ms/met 10-pin size 18 plug cable solder . . . . . . . . . . 1 . . . . .
CONN, circ ms/met clamp str rlf size 18 .625 OD . . . . . . . . . . . . . 1 . . . . .
CONNECTOR & SOCKETS 10-pin remote program select . . . . . 1 . . . . .
CONNECTOR & SOCKETS 14-pin . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
PLATE, ident front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
RECEPTACLE, twist lock assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
RECEPTACLE, male gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE, female gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
NAMEPLATE, switch membrane LX and DX models . . . . . . . . . . 1
NAMEPLATE, switch membrane SD model . . . . . . . . . . . . . . . . . 1
NAMEPLATE, switch membrane LX and DX models . . . . . . . . . . . . . . . . . .
NAMEPLATE, switch membrane SD model . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB, encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
WINDTUNNELS w/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL, caution incorrect voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LABEL, warning electric shock power cord . . . . . . . . . . . . . . . . . . . 1
RELAY, encl 120 VAC DPDT 10A/120VAC 8-Pin Flange Mtg . . . 1
CLAMP, hose .375 − .450 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
HOSE, nprn brd no. 1 x .250 ID x 18.00 . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
1
1
1
1
1
1
2
1
2
1
1
1
1
1
2
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement
Parts. Model and serial number required when ordering parts from your local distributor.
OM-2222 Page 78
Return To Table Of Contents
. Hardware is common and
not available unless listed.
1
2
7
35
6
34
3
4
8
5
11
9
10
33
36
31
32
12
30
13
29
28
27
26
14
15
25
16
24
36
17
23
18
22
21
20
19
ST-802 006-D
Figure 13-2. Windtunnels w/Components
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460 400 CE
Figure 13-2. Windtunnels w/Components
(Figure 13-1 Item 39)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
. . . . . . HD1 . . . . . 182 918
. . . . . . . . . . . . . . . +182 206
. . . . R1,C5,6 . . . 175 194
. . . . . . D1,2 . . . . . 185 775
. . . . . . . . . . . . . . . . 182 208
. . . . . . . T3 . . . . . . 182 667
. . . . . . . . . . . . . . . . 183 073
. . . . . . . . . . . . . . . . 182 499
. . . . . . . . . . . . . . . . 182 806
. . . . . . C3,4 . . . . . 174 980
. . . . . . . T1 . . . . . . 183 014
. . . . . . . L2 . . . . . . 183 009
. . . . . . . L1 . . . . . . 187 522
. . . . . . PC9 . . . . . 187 264
. . . . . . . . . . . . . . . . 187 463
. . . . . . C1 . . . . . 186 549
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
TRANSDUCER, current 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
TRANSFORMER, coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
INSULATOR, PC card HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
ENCLOSURE, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
BRACKET, mtg contactor/capacitor/PC board . . . . . . . . . . . . . 1 . . . . .
CAPACITOR, elctlt 2700uf 420VDC . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
TRANSFORMER, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
STABILIZER, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
CIRCUIT CARD ASSEMBLY, input filter . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, filter board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR, polyp .27uf 1000VDC . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
Return To Table Of Contents
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
OM-2222 Page 79
Quantity
Model
Item
No.
Dia.
Mkgs.
Part
No.
Description
230/460
400 CE
Figure 13-2. Windtunnels w/Components
(Figure 13-1 Item 39) (Continued)
. . . 17 . . . . . . . . . . . . . . . . 025 248
. . . 18 . . . . . . CT1 . . . . . 175 199
. . . 19 . . . . . . . . . . . . . . . . 177 547
. . . 20 . . . . . . . . . . . . . . . . 175 140
. . . 21 . . . . . . . . . . . . . . . . 181 197
. . . 22 . . . . . . L3,4 . . . . . 204 685
. . . 23 . . . . . . . . . . . . . . . . 109 056
. . . 24 . . . . . . . . . . . . . . . +187 460
. . . 25 . . . . . . . . . . . . . . . . 188 008
. . . 26 . . . . . . . . . . . . . . . . 141 690
. . . 27 . . . . . . PC7 . . . . . 189 135
. . . . . . . . . . . . . F1 . . . . . . 012 633
. . . . . . . . . . . . . . . . . . . . . . 196 455
. . . . . . . . . . . PLG19 . . . . 115 092
. . . . . . . . . . . PLG20 . . . . 131 054
. . . 28 . . . . . . SR1 . . . . . 179 629
. . . 29 . . PM1,2/PC4,5 . 179 628
. . . . . . . . . PLG15, 16 . . 115 094
. . . . . . . . . . . RT1,2 . . . . 173 632
. . . 30 . . . . . . . . . . . . . . . . 173 631
. . . 31 . . . . . . . . . . . . . . . . 196 957
. . . 32 . . . . . . . . . . . . . . . . 185 587
. . . 33 . . . . . . . . . . . . . . . . 211 493
. . . . . . . . . . . . . . . . . . . . . . 173 763
. . . 34 . . . . . . . . . . . . . . . . 188 361
. . . 35 . . . . . . . . . . . . . . . . 175 194
. . . 36 . . . . . . . . . . . . . . . . 185 836
. . . 36 . . . . . . . . . . . . . . . . 185 835
. . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . BUSHING, snap-in CT-mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . BRACKET, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . GASKET, DI-DT rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . COIL, DI-DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . BAR, support PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . GROMMET, scr No. 8/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . CIRCUIT CARD, HF (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . . . FUSE, mintr gl 1A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . . . POINT, spark gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . KIT, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . .
. . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . BUS BAR, diode IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . BUS BAR, diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . CONTACTOR, def prp 40A 8P . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STAND-OFF, No. 10-32 x 1.418 lg . . . . . . . . . . . . . . . . . . . . . . . 8
. . Bus Bar, diode heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . RESISTOR/CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . 1 . . . . .
. . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning exploding parts . . . . . . . . . . . . . . . . . . . . . . . . . 2
2
1
1
1
1
2
2
1
1
2
1
1
2
1
1
1
1
2
2
1
1
1
1
1
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2222 Page 80
Return To Table Of Contents
Effective January 1, 2003
(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.
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.
Your distributor also gives
you ...
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.
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.
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
Maxstar 150
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 & SAF 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 8/03
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 to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2003 Miller Electric Mfg. Co.
1/03
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