Miller Sti 203 CE Owner’s Manual

OM-255 441D
2013−02
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
STi 203
CE
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
Miller Electric manufactures a full line of
welders and welding related equipment. For
information on other quality Miller products, contact your local Miller
distributor to receive the latest full line catalog or individual catalog sheets.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3-2. IP Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
4-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
4-3. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-5. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-6. Stick DCEP (Direct Current Electrode Positive) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-8. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-9. Connecting To 3-Phase Engine Generator w/400 Volt Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-2. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-3. Lift-Arc Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4. Stick Start Procedure − Scratch Start Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-6. DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-2. High Temperature Help Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-3. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 8 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 9 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . . . 22
9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter
Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 11 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that
the product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
STi 203
059016015
Council Directives:
•
2006/95/EC Low Voltage
•
2004/108/EC Electromagnetic Compatibility
•
2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
•
IEC 60974­1 Arc Welding Equipment ­ Welding Power Sources: edition 3, 2005­07.
•
IEC 60974­10 Arc Welding Equipment ­ Electromagnetic Compatibility Requirements: edition 2.0, 2007­08.
•
EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields
(0Hz­300Hz)
EU Signatory:
January 2nd , 2013
___________________________________________________________________________________
Massimigliano Lavarini
Date of Declaration
ELECTRONIC ENGINEER R&D TECH. SUPPORT
956 172 019
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-255 441 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-255 441 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
BATTERY EXPLOSION can injure.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D
D
D
D
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-255 441 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures
in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-255 441 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
OM-255 441 Page 5
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
2-2. Miscellaneous Symbols And Definitions
A
Amperes
V
Volts
Voltage Input
Voltage Output
Off
Remote
Lift-Arc Start
(GTAW)
Protective Earth
(Ground)
Process
High Temperature
Increase/Decrease
Of Quantity
On
Percent
Positive
Negative
Hertz
Arc Force (DIG)
Direct Current
Line Connection
Alternating
Current
X
Duty Cycle
U1
Primary Voltage
U0
Rated No Load
Voltage (Average)
OM-255 441 Page 6
I
Hz
IP
Output/On
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
I2
Rated Welding
Current
U2
Conventional Load
Voltage
I1eff
Maximum Effective
Supply Current
SECTION 3 − SPECIFICATIONS
3-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
!
This equipment does not comply with IEC 61000−3−12. If it is connected to a public low voltage system, it is the responsibility of
the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment can be connected.
ce-emc 2 2011-09
3-2. IP Rating
IP Rating: 23.This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless sheltered.
Operating temperature Range: 14° F (-10° C) to 104° F (40° C). Ratings were developed at an ambient temperature of 20° C to 25° C.
3-3. Specifications
Welding
Process
Stick
Rated Output
Welding
Amperage
Range
200 A @ 28
VDC,
40% Duty
Cycle
5 − 200
TIG
Max.
OpenCircuit
Voltage
(U0)
200 A @ 18
VDC,
40% Duty
Cycle
Amperes Input At Rated Output, 50/60Hz
380
400
440
13.5
12.8
11.5
KVA
KW
Dimensions
8.86
6.51
Length: 460 mm
(18.1 in.)
Width: 190 mm
(7.48 in.)
85 VDC
8.7
8.3
7.5
5.73
4.20
Weight
17 Kg
(37.5 lb)
Height: 345 mm
(13.6 in.)
OM-255 441 Page 7
3-4. 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.
100
95
90
85
80
75
70
65
VOLTS
60
TIG/ Stick Max
55
50
45
40
35
TIG Min
30
25
20
15
Stick Min
10
5
0
0
20
40
60
80
100
120
140
160
180
200
220
AMPERES
3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, output stops and
cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before
welding.
250
OUTPUT AMPERES
STICK/TIG
200
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
150
100
50
0
10
50
100
% DUTY CYCLE
4 Minutes Welding
6 Minutes Resting
Overheating
A or V
0
15
Minutes
OM-255 441 Page 8
OR
Reduce Duty Cycle
SECTION 4 − INSTALLATION
4-1. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the rear of the machine. Use the rating labels to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Selecting A Location
1
Line Disconnect Device
Locate unit near correct input
power supply.
!
Location And Airflow
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
460 mm
(18 in.)
460 mm
(18 in.)
246 381-A / 956142915_1-A
OM-255 441 Page 9
4-3. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn,
damaged,
undersized, or poorly
spliced cables.
30 m (100 ft) or Less
60 m
(200 ft)
70 m
(250 ft)
90 m
(300 ft)
105 m
(350 ft)
120 m
(400 ft)
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
mm2 (AWG)
mm2 (AWG)
100
20 (4)
20 (4)
20 (4)
30 (3)
35 (2)
50 (1)
60 (1/0)
60 (1/0)
150
30 (3)
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
95 (3/0)
200
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
120 (4/0)
Welding
Amperes
* This
45 m
(150 ft)
10 − 100% Duty Cycle
mm2 (AWG)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***For distances longer than those shown in this guide, call a factory applications representative.
Milan Ref. S-0007-J 2011−07
4-4. Remote 14 Receptacle Information
A
B
K
14 Socket*
J
Socket Information
I
H
C L N
M
D
G
E F
REMOTE
OUTPUT
CONTROL
CHASSIS
956142915_1-A
OM-255 441 Page 10
A
Contactor control 24 volts DC.
B
Contact closure to A completes 24 volt DC
contactor control circuit and enables output.
C
Output to remote control; +5 volts DC output to
remote control.
D
Remote control circuit common.
E
0 to +5 volts DC input command from remote
control.
G
Chassis common.
4-5. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections
5
4
!
Turn off power before making connections.
1
Positive (+) Weld Output
Terminal
Connect work lead to positive weld
output terminal.
6
2
3
Connect TIG torch to negative weld
output terminal.
3
4
Negative (−) Weld Output
Terminal
Gas Cylinder
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
5
6
Regulator/Flowmeter
Flow Adjust
Typical flow rate is 15 cubic feet per
hour (7.1 liters per minute).
Connect torch gas hose to regulator/flowmeter.
1
7
Gas Valve
Valve controls gas preflow and
postflow. Open valve on torch just
before welding.
2
Tools Needed:
7
21 mm (11/16, 1-1/8 in.)
OM-255 441 Page 11
4-6. Stick DCEP (Direct Current Electrode Positive) Connections
!
Turn off power before making connections.
1
Negative (−) Weld Output
Terminal
Connect work lead to negative weld
output terminal.
2
Positive (+) Weld Output
Terminal
Connect electrode holder to positive weld output terminal.
3
Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Section 4-4).
2
1
4-7. Electrical Service Guide
. Actual input voltage cannot exceed -10% of minimum, or +10% of maximum input voltages indicated in table.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
Three-Phase, 40% Duty Cycle
380−440 +/− 10%
Input Voltage (V)
Input Amperes (A) At Rated Output
13.5−11.5
Max Recommended Standard Fuse Rating In Amperes
1
Time Delay Fuses 2
10
Normal Operating Fuses 3
20
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
13 (2.63 mm2)
(3.5)
13 (2.63 mm2)
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-255 441 Page 12
4-8.
Connecting Input Power
3
!
Installation must meet all National
and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input power before connecting input
conductors from unit.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
= GND/PE Earth Ground
4
For Three-Phase Operation
7
1
2
3
2
4
5
6
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
L1
3
L2
5
L3
6
1
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
7
Over-Current Protection
Select type and size of over-current
protection using Section 4-7 (fused disconnect switch shown).
Close and secure door on disconnect device. Remove lockout/tagout device, and
place switch in the On position.
Tools Needed:
4-9. Connecting To 3-Phase Engine Generator w/400 Volt Output
Installation must meet all National and Local Codes − have only qualified persons make this installation.
. Obtain a 400 volt plug that matches the receptacle on the engine generator. Install the plug on the cord of the welding power source according
to the plug manufacturer’s instructions.
Generator Requirements
• Engine generator must provide the correct input amperage (see Section 4-7).
• Frequency must be between 50 and 60 Hz
NOTICE − Make sure welding power source is off during engine generator start-up. Do not turn on the welding power source until the generator has
reached normal operating speed.
OM-255 441 Page 13
SECTION 5 − OPERATION
5-1. Controls
4
1
8
2
7
4
3
5
6
9
Green on nameplate indicates a TIG function, Gray indicates a Stick function.
1 Power On Light
The power on light turns on when power is
turned on.
2 High Temperature Light (LED)
Light comes on if unit overheats. Welding
can resume when unit has cooled (see Sections 3-5 and 6-2).
3 Ammeter/Voltage Display (Meter)
Upon power up, selected amperage is dis-
played for three seconds, after which 000 is
displayed.
. While welding, actual arc amperage is
displayed, not the amperage selected
with the Amperage control.
4 Amperage/Voltage Display Push
Button
Push button to change between amperage
and voltage display.
5 Voltage Display Indicator LED
LED is lit when voltage is being displayed.
6 DIG Control
See Section 5-6.
7 Amperage Control
See Section 5-5.
8 Process Controls
See Section 5-2.
See Section 3-5.
9 Power Switch
Use switch to turn unit and indicator light
On/Off.
956142915_2-A
OM-255 441 Page 14
5-2. Process Control
1
Process Control
Use the Process control to select
the Stick process (up), or the TIG
Lift Arc process (down).
1
Stick (SMAW) - This is a DCEP (direct current electrode positive) process. Make connections according
to Section 4-6.
TIG Lift-Arct - This is a DCEN (direct current electrode negative)
process in which the electrode
must come in contact with the work
piece to initiate an arc (see Section
5-3). Make connections according
to Section 4-5.
5-3. Lift-Arc Start Procedure
Lift-Arc Start
With Lift-Arct selected, start arc
as follows:
Lift-Arc Start Method
1
“Touch”
1−2
Seconds
2
1
TIG Electrode
2
Workpiece
Turn gas on. Touch tungsten electrode to workpiece at weld start
point. Hold electrode to workpiece for 1-2 seconds, and slowly
lift electrode. Arc is formed when
electrode is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting
contaminated.
Application:
Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to replace the scratch method.
Do NOT Strike Like A Match!
OM-255 441 Page 15
5-4.
Stick Start Procedure − Scratch Start Technique
With Stick selected, start arc as follows:
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
to high. If electrode sticks to workpiece, use
a quick twist to free it.
1
!
2
3
For models with stock number 907
220, normal open-circuit voltage (80
volts) is present before electrode
touches workpiece.
For models with stock numbers 907 036 and
907 037, normal open-circuit voltage is not
present before electrode touches workpiece; only a low sensing voltage is present
between electrode and workpiece.
5-5. Amperage Control
1
1
A (Amperage Control)
Rotate knob clockwise to increase
amperage (Min-200 amps).
Min
5-6. DIG Control
1
1
DIG Control
Control increases SMAW short-circuit amperage at low arc voltage.
This allows the operator to use a
very short arc length without sticking the electrode.
Set control at 0 for normal welding
amperage. Turn clockwise to increase short-circuit amperage.
OM-255 441 Page 16
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
!
Disconnect power before maintaining.
. Maintain more often during severe conditions.
A. Welding Power Source
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Δ = Repair
l = Replace
Every
3
Months
nl Labels
n l Gas Hoses
Every
3
Months
nΔ lCables And Cords
Every
6
Months
!
Do not remove case when
blowing out inside of unit
(see Section 6-3) .
~:Durning heavy service, clean monthly.
6-2. High Temperature Help Display
1
2
1
-- -
2
High Temperature Light (LED)
Meter Help Display
When unit over heats, High Temperature
light turns on and unit emits an audible
beep. The meter displays three dashes as
shown. Unit shuts down and fans run until
temperature drops within normal operating range (see Section 3-5).
NOTICE − Wait at least four minutes before checking to see if temperature is within normal operating range.
956142915_2-A
OM-255 441 Page 17
6-3. Blowing Out Inside Of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
6-4. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-8).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-8).
Check for proper input power connections (see Section 4-8).
No weld output; Output LED on.
Input voltage outside acceptable range of variation (see Section 4-7).
No weld output; Overtemp LED on.
Unit overheated. Allow unit to cool with fan On (see Sections 3-5).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-3).
Clean and tighten all weld connections (see Section 4-3).
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 9).
Use properly prepared tungsten (see Section 9).
Reduce gas flow rate (see Section 4-5).
Tungsten electrode oxidizing and not re- Shield weld zone from drafts.
maining bright after conclusion of weld.
Allow adequate postflow time to shield tungsten while it cools, after welding stops.
Check and tighten all gas fittings (see Section 4-5).
Water in torch. Refer to torch manual.
OM-255 441 Page 18
SECTION 7 − ELECTRICAL DIAGRAMS
Figure 7-1. Circuit Diagram
956142913-B
OM-255 441 Page 19
SECTION 8 − HIGH FREQUENCY
8-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG
high_freq 5/10 − S-0693
8-2. Installation Showing Possible Sources Of HF Interference
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
5
6
Best Practices
Not Followed
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
OM-255 441 Page 20
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
8-3. Recommended Installation To Reduce HF Interference
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece if
required by
codes.
9
Best Practices Followed
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case (clean paint
from around hole in case, and use case
screw), work output terminal, line disconnect device, input supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
OM-255 441 Page 21
SECTION 9 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2011-06
Whenever possible and practical, use DC weld output instead of AC weld output.
9-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (1 mm)
Up to 25
Up to 20
.020 in. (1 mm)
15-40
15-35
.040 in. (1 mm)
25-85
20-80
1/16 in. (1.6 mm)
50-160
50-150
3/32 in. (2.4 mm)
130-250
135-235
1/8 in. (3.2 mm)
250-400
225-360
5/32 in. (4.0 mm)
400-500
300-450
3/16 in (4.8 mm)
500-750
400-500
1/4 in. (6.4 mm)
750-1000
600-800
♦Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC
Welding With Inverter Machines
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
Radial Grinding
Causes Wandering Arc
2-1/2 Times
Electrode Diameter
1
3
2
1
Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
2
Tungsten Electrode
A 2% ceriated tungsten is recommended.
4
Wrong Tungsten
Preparation
Ideal Tungsten Preparation − Stable Arc
3
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
OM-255 441 Page 22
SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW)
10-1. Positioning The Torch
!
Grinding the tungsten electrode
produces dust and flying sparks
which can cause injury and start
fires. Use local exhaust (forced
ventilation) at the grinder or wear
an approved respirator. Read
MSDS for safety information.
Consider using cerium or lanthanum based tungsten instead of
thoriated. Thorium dust contains
low-level radioactive material.
Properly dispose of grinder dust
in an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
1
Workpiece
3
2
4
90°
Make sure workpiece is clean before
welding.
1
2
Work Clamp
Place as close to the weld as possible.
3
4
5
6
10−15°
4
5
6
10−25°
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten according
to Section 9.
Guidelines:
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate
shielding gas coverage. (For example,
if tungsten is 1/16 in. diameter, gas cup
should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the
tungsten extends out gas cup of torch.
1/16 in.
3/16 in.
Bottom View Of Gas Cup
The tungsten extension should be no
greater than the inside diameter of the
gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
OM-255 441 Page 23
10-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
15°
Tilt torch
Remove rod
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
10-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20°
90°
70°
75°
20°
10°
15°
Corner Joint
Lap Joint
20-40°
90°
75°
75°
15°
15°
30°
ST-162 003 / S-0792
OM-255 441 Page 24
SECTION 11 − STICK WELDING (SMAW) GUIDELINES
11-1. Stick Welding Procedure
!
Weld current starts when
electrode touches workpiece.
!
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.
Equipment Needed:
Tools Needed:
. Always wear appropriate per1
Constant Current
Welding Power Source
sonal protective clothing.
Workpiece
Make sure workpiece is clean before welding.
2
3
Work Clamp
Electrode
A small diameter electrode requires less current than a large
one. Follow electrode manufacturer’s instructions when setting weld
amperage (see Section 11-2).
4
5
6
5
4
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.
2
7
3
Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
6
1
7
stick 2010−02 − 151 593
OM-255 441 Page 25
6013
7014
7018
7024
Ni-Cl
308L
ALL
DEEP
EP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
MED
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
NI-CL
EP
FLAT
HORIZ
FILLET
ALL
308L
EP
ALL
USAGE
EP
6011
AC
PENETRATION
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
DC*
6010
ELECTRODE
450
400
350
300
AMPERAGE
RANGE
250
200
150
POSITION
6010
&
6011
100
50
DIAMETER
ELECTRODE
11-2. 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
11-3. Striking an Arc
1
2
3
Electrode
Workpiece
Arc
Scratch Technique
1
2
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.
Tapping Technique
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
1
2
3
S-0049 / S-0050
OM-255 441 Page 26
11-4. Positioning Electrode Holder
1
2
End View Of Work Angle
Side View Of Electrode Angle
1
10°-30°
90°
2
90°
Groove Welds
10°-30°
45°
1
2
45°
Fillet Welds
S-0060
11-5. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
2
3
5
1
S-0053-A
11-6. 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.
2
3
4
5
4
5
No Overlap
Good Penetration into Base
Metal
1
S-0052-B
OM-255 441 Page 27
11-7. Conditions That Affect Weld Bead Shape
. 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
Electrode Angle
Drag
Spatter
Arc Length
Too Short
Normal
Too Long
Slow
Normal
Fast
Travel Speed
S-0061
11-8. Electrode Movement During Welding
. Normally,
2
1
1
2
3
3
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.
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.
S-0054-A
OM-255 441 Page 28
11-9. Groove (Butt) Joints
1
Tack Welds
Prevent edges of joint from drawing together ahead of electrode by
tack welding the materials in position before final weld.
1
2
2
Square Groove Weld
Good for materials up to 3/16 in. (5
mm) thick.
3
1/16 in.
(1.6 mm)
Single V-Groove Weld
Good for materials 3/16 − 3/4 in.
(5-19 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.
30°
Create 30 degree angle of bevel on
materials in V-groove welding.
4
Good for materials thicker than
3/16 in. (5 mm).
4
3
Double V-Groove Weld
S-0062
11-10. Lap Joint
1
2
Electrode
Single-Layer Fillet Weld
Move electrode in circular motion.
3
30°
Or Less
30°
Or Less
1
1
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
S-0063 / S-0064
11-11. Tee Joint
1
2
Electrode
Fillet Weld
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.
For maximum strength weld both
sides of upright section.
1
2
45°
Or
Less
1
2
3
3
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
11-8. Remove slag before making
another weld pass.
S-0060 / S-0058-A / S-0061
OM-255 441 Page 29
11-12. Weld Test
1
2
3
Vise
Weld Joint
Hammer
Strike weld joint in direction shown.
A good weld bends over but does
not break.
3
3
2 To 3 in.
(51-76 mm)
1/4 in.
(6.4 mm)
2
1
2 To 3 in.
(51-76 mm)
2
1
S-0057-B
11-13. Troubleshooting
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.
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.
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.
OM-255 441 Page 30
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
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.
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
Possible Causes
Corrective Actions
Unsteady hand.
Use two hands. Practice technique.
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
Corrective Actions
Excessive heat input.
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.
OM-255 441 Page 31
SECTION 12 − PARTS LIST
. Hardware
is common and
not available unless listed.
10
11
9
24
12
2
13
14
15
8
7
6
23
22
16
21
5
1
4
3
17
Fig 12-3
18
25
19
Fig 12-4
20
Fig 12-2
956142915_3-B
Figure 12-1. Main Assembly
OM-255 441 Page 32
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
1 . . . . . . . . . . . . . . +156121039
2 . . . . . . . . . . . . . . . . . . 195585
3 . . . . . . . . . . . . . . . . . . 199478
4 . . . . . . . . . . . . . . . 956142676
5 . . . . . . . . . . . . . . . . . . 179310
6 . . . . . . . . Z1 . . . . 57059007
7 . . . . . . . PC2 . . . 057084138
8 . . . . . . . . T1 . . . . 57059006
9 . . . . . . . . . . . . . . . 156005142
10 . . . . . . PC1 . . . 057084137
11 . . . . . . PC4 . . . . 56130021
12 . . . . . . . . . . . . . . 156005139
13 . . . . . . TP1 . . . . 56159027
14 . . . . . . . . . . . . . . 156005138
15 . . . . . . FM1 . . . . 56126076
16 . . . . . . . . . . . . . . . 57014221
17 . . . . . . . . . . . . . . . . Fig 12-3
18 . . . . . . . S1 . . . . . . 128756
19 . . . . . . . . . . . . . . . . Fig 12-4
20 . . . . . . . . . . . . . . . . Fig 12-2
21 . . . . . . . . . . . . . . 756005028
22 . . . . . . . . . . . . . . 156118058
23 . . . . . . . . . . . . . . 756084029
24 . . . . . . . . . . . . . . . . . 195663
25 . . . . . . . . . . . . . . 058066104
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Miller 6.000 X 2.500 Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Side STi 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Gen. Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC2 Circuit Card Assy, Secondary Inverter . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support, Inverter PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC1 Circuit Card Assy, Primary Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC4 Line Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support, Line Input Filter PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Motor, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Primary 4 Core 2.5mm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Rear w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl 3Pst 40A 600 VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . .
Base, Assembly w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support, Intermediate, Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intermediate, Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mylar insulating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strap, Shoulder Assy 6 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrode Holder/Ground Clamp Cable Set, 3 Mt . . . . . . . . . . . . . . . . . . . .
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
+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-255 441 Page 33
. Hardware
4
is common and
not available unless listed.
3
2
1
12
11
10
9
8
5
7
6
Figure 12-2. Panel, Front w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
956142915_4-A
Quantity
12-2. Panel, Front w/Components (Figure 12-1 Item 1)
1 . . . . . . . . . . . . . . . . . . 194242 . . . . Panel, Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . 356029208 . . . . Nameplate, Lower STi 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 . . . . . . . . . . . . . . . 156118059 . . . . Panel, Front, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 . . . . . . . RC1 . . . 056076259 . . . . Female 14-Pin Receptacle, Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . 56076257 . . . . Female Socket, Dinse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . . . . . . . . . . . 207253 . . . . Plug, Gas Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . . . . . 193920 . . . . Knob, Pointer .840 Dia X .250 ld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . . . . . . . . . . . . 193919 . . . . Knob, Pointer 1.250 Dia X .250 ld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 . . . . . . . . . . . . . . . 656014013 . . . . Cover, Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . . . . . . . . 356029247 . . . . Nameplate, Upper STi 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . . 156118084 . . . . Panel, Front Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . . . PC30 . . 057084178 . . . . PC3 Circuit Card Assy, Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-255 441 Page 34
. Hardware
is common and
not available unless listed.
6
5
4
3
2
1
956142915_5-A
Figure 12-3.Panel, Rear w/Components
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-3. Panel, Rear w/Components (Figure 12-1 Item 2)
1
2
3
4
5
6
. . . . . . . . . . . . . . . V16118098
. . . . . . . . . . . . . . . . . . 194242
. . . . . . . . . . . . . . . . . . 207723
. . . . . . . . . . . . . . V15024100
. . . . . . . . . . . . . . . 656089039
. . . . . . . . . . . . . . . 956142657
....
....
....
....
....
....
Panel, Rear Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front/Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug, Gas Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Rear Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-255 441 Page 35
. Hardware
is common and
not available unless listed.
1
2
3
Figure 12-4. Base Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
956142915_6-A
Quantity
Figure 12-4. Base Assembly
(Figure 12-1 Item 5)
1 . . . . . . . . . . . . . . . 156006060 . . . . Base, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . V56110090 . . . . Mount, Nprn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 . . . . . . . . . . . . . . . 956142662 . . . . Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-255 441 Page 36
Notes
Notes
Effective January 1, 2013
(Equipment with a serial number preface of MD or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, ITW Welding Products Italy warrants to its original retail
purchaser that new Miller equipment sold after the effective date
of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser or one
year after the equipment is shipped to a European distributor or
eighteen months after the equipment is shipped to an
International distributor.
1.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Auto-Darkening Helmet Lenses (No Labor)
Migmatic 175
HF Units
Water
Coolant
Systems
(EU
Models,
Non-Integrated)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
5.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
Inverter Power Sources (Unless Otherwise Stated)
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Transformer/Rectifier Power Sources
Water Coolant System (Integrated)
2 Years — Parts
*
*
*
*
4.
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules with
exclusion of STR, Si, STi, STH and MPi series.
Automatic Motion Devices
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Powered Air Purifying Respirator (PAPR) Blower
Unit (No Labor)
Racks
Running Gear and Trailers
Subarc Wire Drive Assemblies
Water
Coolant
Systems
(USA
Models,
Non-Integrated)
Work Stations/Weld Tables (No Labor)
6 Months — Parts
*
Batteries
90 Days — Parts
*
Accessory (Kits)
*
Canvas Covers
*
Induction Heating Coils and Blankets
*
MIG Guns
*
Remote Controls
*
Replacement Parts (No Labor)
*
Spoolmate Spoolguns
*
Cables and Non-Electronic Controls
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, switches, slip
rings, relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
5 Years Parts — 3 Years Labor
*
2.
6.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at ITW Welding Products
Group Europe or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
milan_warr 2013−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
Country
Zip/Postal Code
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Italy S.r.l.
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
© 2013 Miller Electric Mfg. Co. 2013−01
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it