Miller | LC652140 | Owner Manual | Miller SUMMIT ARC 1000 User manual

Miller SUMMIT ARC 1000 User manual
OM-2221
186 183L
February 2004
Processes
Submerged (SAW) Welding
Description
Arc Welding Power Source

Summit Arc 1000/1250
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. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Manufacturer’s Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Weld Output Terminals and Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Selecting AC or DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Terminal Strip TE3 and Remote 14 Receptacle RC7 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. Connecting Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. 115 Volts AC Receptacle And Circuit Breaker (460 And 575 Volt Input Models) . . . . . . . . . . . . . . . . . .
2-13. 230 Volts AC Receptacle And Circuit Breakers (400 Volt Input Models) . . . . . . . . . . . . . . . . . . . . . . . .
2-14. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16. Matching Primary Lines L1, L2, And L3 When Using Multiple Units . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − MAKING WELD OUTPUT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Work And Electrode Cable Connections For Single DC or AC Arcs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Using Multiple Units: DC Lead Arc, One or More AC Trailing Arcs
With Separate Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Using Multiple Units: Two or More AC Arcs With Separate Electrodes . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Using Multiple Units: Parallel DC Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Using Multiple Units: Parallel AC Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Synchronizing Outputs For Parallel AC Arcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Using Non-Parallel AC Arcs Terminal Strip TE4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Control Board PC1 Connections For Non-Parallel AC Arcs Or Parallel Synchronized AC Arcs . . . . .
3-9. Testing AC Output Units For Correct Phasing Prior to Parallel Operation . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Front Panel Controls (Non-CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Front Panel Controls (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Fuses F1 And F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Access Area Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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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:
Summit ArcE 1000/1250
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 72/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Electromagnetic Compatibility Directives: 89/336, 92/31/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1993
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(April 1995 − 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: January 1997
European Contact:
Telephone:
Fax:
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.
Marks a special safety message.
Means “Note”; not safety related.
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.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Only qualified persons should install, operate, maintain, and
repair this unit.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
During operation, keep everybody, especially children, away.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
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.
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.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
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).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Keep your head out of the fumes. Do not breathe the fumes.
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.
When making input connections, attach proper grounding conductor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
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.
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.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
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.
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-2221 Page 1
ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
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.
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.
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Pacemaker wearers keep away.
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.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
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).
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.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
OM-2221 Page 2
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
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.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
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.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
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.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
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
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:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
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:
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-2221 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-2221 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.
Identifie un message de sécurité particulier.
Signifie « NOTA » ; n’est pas relatif à la sécurité.
2-2. Dangers relatifs au soudage à l’arc
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.
N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
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.
Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
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.
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.
Ne jamais toucher aux pièces électriques sous tension.
Porter des gants et des vêtements de protection secs et exempts de
trous.
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.
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.
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).
Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
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.
Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
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.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
Ne pas s’enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
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.
Se tenir à distance des fumées et ne pas les inhaler.
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.
Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
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.
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.
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.
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-2221 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.
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).
Porter des lunettes de sécurité à écrans latéraux sous le masque.
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.
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.
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.
Ne pas toucher les pièces chaudes à main nue.
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.
Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
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.
Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
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).
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.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
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.
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.
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.
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-2221 Page 6
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.
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.
Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
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.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
Ne jamais poser une torche de soudage sur une bouteille de gaz.
Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
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.
Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
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.
Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
Se tenir à l’écart des organes mobiles comme les
ventilateurs.
Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
Ne pas installer l’appareil à proximité de produits inflammables.
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.
N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
Utiliser un engin de capacité adéquate pour lever
l’appareil.
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.
Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
Faire régulièrement contrôler et entretenir l’installation.
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.
Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
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.
Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
Se tenir à l’écart des pièces mobiles.
Se tenir à l’écart des points de coincement tels
que les dévidoirs.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
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).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
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.
Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
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.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-2221 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-2221 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 − INSTALLATION
NOTE
With 60 Hz input power, the ac weld output of this unit is 10 Hz. With 50 Hz input,
the ac weld output is 8.33 Hz.
3-1. Specifications
AC or DC
Rated Output
1000 A at 44 V,
100% Duty Cycle;
1250 A at 44 V,
60% Duty Cycle
Voltage
Range in
CV Mode
Amperage
Range in
CC Mode
Max. OpenCircuit
Voltage
25−44 V
250−1250 A
71 V
RMS Amps Input at Rated Load Output, 3-Phase at
NEMA Load
Voltages and Class I Rating
380/400/415 V
(50/60 Hz)
460 V
(60 Hz)
500 V
(50/60 Hz)
575 V
(60 Hz)
KVA
KW
143
(3*)
124
(3*)
114
(3*)
100
(3*)
98
(2.37*)
53
(0.95*)
*While idling
3-2. Duty Cycle and Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
100% Duty Cycle At 1000 Amperes
Continuous Welding
If unit overheats, high temperature
shutdown light turns On, thermostat(s) opens, output stops, and
cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.
Exceeding duty cycle can
damage unit and void warranty.
Overheating
A/V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 − SA-181 560
Return To Table Of Contents
OM-2221 Page 9
3-3. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
A. CC Mode
AC Output
DC Output
B. CV Mode
AC Output
DC Output
va_curve1 4/95 − SA-189 242 / SA-189 240 / SA-189 243 / SA-189 241
OM-2221 Page 10
Return To Table Of Contents
3-4. Dimensions And Weight
A
Dimensions
Height* 44 in (1118 mm)
Width*
27-1/4 in (692 mm)
Depth*
46 in (1168 mm)
A
1-7/8 in (48 mm)
B
44-1/8 in (1120 mm)
C
11/16 in (17 mm)
D
26-1/16 in (662 mm)
E
4 holes:
21/32 in (6.5 mm) dia
Weight
1225 lb (540 kg)
B
E
Front
C
D
* Includes lifting eye, handles, hardware, etc.
3-5. Symbol Definitions
NOTE
A
Some symbols are found only on CE products.
Amperage
V
Voltage
Hz
Hertz
Direct Current
(DC)
Alternating Current
(AC)
Panel/Local
Line Connection
Three Phase
Output
On
Voltage Input
Off
Submerged Arc
Welding (SAW)
Read Operator’s
Manual
Remote
Duty Cycle
Percent
U0
Rated No-Load
Voltage (Average)
U2
Conventional Load
Voltage
I2
Rated Welding
Current
Protective Earth
(Ground)
I1eff
Maximum Effective
Supply Current
3-Phase Power
Source With
AC/DC Output
Temperature
Ventilating And Air
Circulating Fan
Degree Of
Protection
Air Carbon Arc
Cutting (CAC-A)
Shielding Metal Arc
Welding (SMAW)
Increase
IP
U1
X
Rated Supply
Voltage
Circuit Breaker
I1max
Rated Maximum
Supply Current
Gas Metal Arc
Welding GMAW)
Return To Table Of Contents
OM-2221 Page 11
3-6. Manufacturer’s Rating Label For CE Products
3-7. Selecting a Location
1
2
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
Movement
If using lifting forks, extend forks
beyond opposite side of unit.
1
3
4
OR
Rating Label
Plate Label
Use rating or plate label to determine input power needs.
2
5
Line Disconnect Device
Locate unit near correct input
power supply.
5
Location
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
3
18 in
(460 mm)
4
18 in
(460 mm)
loc_2 3/96 - ST-801 881-A
OM-2221 Page 12
Return To Table Of Contents
3-8. Weld Output Terminals and Selecting Cable Sizes
NOTE
In the table below, when multiple numbers are indicated separated by a hyphen,
the number to the left of the hyphen indicates how many cables are to be used, and
the number to the right indicates the size of the cable to be used. For example,
3-3/0 indicates that 3 cables of 3/0 gauge need to be used for electrode and work
connections.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
Weld Output
Terminals
Turn Off welding power source and disconnect
input power before connecting to weld output terminals.
Electrode
Weld Output
Terminals
Work
Weld Output
Terminals
Requires cable lugs with
5/8 in diameter holes.
100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 − 60%
Duty Cycle
60 − 100%
Duty Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
700
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
4-4/0
800
4/0
2-2/0
2-3/0
2-4/0
3-4/0
3-4/0
4-4/0
4-4/0
900
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
4-4/0
4-4/0
1000
2-2/0
2-3/0
2-4/0
3-3/0
4-3/0
4-4/0
1250
2-3/0
2-4/0
3-3/0
4-3/0
4-4/0
10 − 100% Duty Cycle
15/16 in
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your
distributor for the mm2 equivalent weld cable sizes.
S-0007-E
Return To Table Of Contents
OM-2221 Page 13
3-9. Selecting AC or DC Output
Turn Off welding power
source and disconnect input
power before relinking unit.
2
ÏÏ
Ï
Ï
Ï
Ï
ÏÏÏÏÏÏ
DC Ï ÏÏÏÏ
Ï ÏÏÏÏ
AC
1
ÏÏÏ
Ï
Ï
Ï
ÏÏ
Ï
Ï
Ï
ÏÏ
ÏÏ
ÏÏÏ
ÏÏ
ÏÏÏÏ
Remove top of unit.
1
2
AC/DC Output Selection
Label (Located Inside Unit)
Jumper Links
Locate terminal board inside unit.
Install jumper links for desired output as shown on label.
Securing
nuts must be removed to change the position
of the three jumper links at the
right of the terminal board. To
change the position of the remaining six jumper links, loosen the securing nuts only to allow the slotted jumper links to
be moved. Always securely retighten nuts after links are
moved.
Reinstall top of unit.
See Safety Rules at beginning of
manual for special ac concerns.
Tools Needed:
3/8, 11/16, 7/8 in
ST-801 881-A / Ref. S-185 482
3-10. Terminal Strip TE3 and Remote 14 Receptacle RC7 Information
24 VOLTS AC
REMOTE OUTPUT CONTROL
115 VOLTS AC
Socket
on RC7
Terminal
on TE3
Information
A
A
24 volts, 12 amperes, 60 Hz ac. Protected by circuit breaker CB2.
B
B
Contact closure to A completes 24 volts ac contactor control circuit.
C
C
Command reference; +10 volts dc.
D
D
Remote control circuit common.
E
E
0 to +10 volts dc input command signal from remote control.
I
I
115 volts, 12 amperes, 60 Hz ac. Protected by circuit breaker CB1.
J
J
Contact closure to I completes 115 volts ac contactor control circuit.
K
K
Chassis common.
G
G
Circuit common for 24, 42 and 115 volts ac circuits.
*
L
42 volts, 12 amperes, 60 Hz ac. Protected by circuit breaker CB3.
A/V AMPERAGE
F
*
Current feedback; +1 volt dc per 100 amperes.
VOLTAGE
H
*
Voltage feedback; +1 volt dc per 10 output terminal volts.
*
N
Voltage sensing signal from Work weld output terminal.
*
P
Voltage sensing signal from Electrode weld output terminal.
GND
42 VOLTS AC
REMOTE VOLTAGE SENSING
* Not Used
OM-2221 Page 14
Return To Table Of Contents
3-11. Connecting Remote Control
Turn Off welding power
source and disconnect input
power before opening access door.
1
2
OR
OR
OR
Connect remote control to Remote
14 receptacle. If plug does not fit,
wire cord to terminal strip TE3 (see
Section
3-10
for
terminal
information).
3
4
5
3
Terminal Strip TE3 (Mounted
Inside Access Area)
Lead Being Connected To
TE3
Securing Screw
Strip 3/8 in (10 mm) insulation off
end of lead, insert end into proper
location on TE3, and tighten applicable securing screw.
A
B
C
D
E
G
I
J
K
L
N
P
Close and secure access door.
1
2
A
B
K
J
I
H
C L N
D M
G
E F
Tools Needed:
3
4
Access Door
Remote 14 Receptacle
(Mounted Inside Access Area)
3/8 in
(10 mm)
5
Ref. ST-049 258-C / ST-801 882-A
Return To Table Of Contents
OM-2221 Page 15
3-12. 115 Volts AC Receptacle And Circuit Breaker (460 And 575 Volt Input Models)
1
115 V 12 A AC Receptacle
Power is shared between the duplex receptacle and the 115 volt
output connections at terminal strip
TE3 and the Remote 14 receptacle
(see Section 3-10).
1
2
Circuit Breaker CB1
CB1 protects 115 volts ac receptacle and 115 volts ac portion of terminal strip TE3 and Remote 14 receptacle from overload.
2
Ref. ST-175 086 / Ref. ST-801 882-B
3-13. 230 Volts AC Receptacle And Circuit Breakers (400 Volt Input Models)
1
2
230 V 16 A AC Receptacle
Circuit Breaker CB1
CB1 protects the 115 volts ac portion of terminal strip TE3 and Remote 14 receptacle from overload.
3
Circuit Breaker CB4
CB4 protects the 230 volts ac receptacle from overload.
1
3
2
Ref. ST-175 086 / Ref. ST-801 882-B
OM-2221 Page 16
Return To Table Of Contents
3-14. Electrical Service Guide
Three-Phase, 50/60 Hz
Three-Phase, 60 Hz
Input Voltage
380
400
415
500
460
575
Input Amperes At Rated Output
149
141
136
114
124
100
Time-Delay 2
175
175
150
125
150
110
Normal Operating 3
225
200
200
175
175
150
1/0
1/0
1/0
2
1
3
398 (121)
441 (134)
474 (145)
490 (149)
482 (147)
548 (167)
4
6
6
6
6
6
Max Recommended Standard Fuse Rating In Amperes 1
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1999 National Electrical Code (NEC)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “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).
Return To Table Of Contents
OM-2221 Page 17
3-15. Connecting Input Power
When using multiple units which
will be linked with the synchronizing terminal strip TE4, ensure
that primary input power conductors are connected to each
unit in the same sequence (L1 to
L1, L2 to L2, and L3 to L3.)
See Section 3-16 for information on
testing for proper primary phase
sequence.
Disconnect and lockout/tagout input power before connecting input conductors
from unit.
Have only qualified persons
make this installation.
Check input voltage available at
site.
Remove left side panel.
1
Input And Grounding
Conductors
2
Line Disconnect Device Of
Proper Rating
2
4
See Section 3-14.
6
L1
3
Access Hole And Strain Relief
Connector
4
Input Conductors
5
Grounding Conductor (Green
or Green With Yellow Stripe)
L2
L3
Always connect
grounding
conductor first.
1
= GND/PE
Insert conductors through strain relief and tighten screws.
L1
L2
L3
6
Three-Phase Input Contactor
7
Ground Terminal
Connect grounding conductor to
ground terminal on frame first. Then
connect input conductors to line terminals on contactor. Secure strain
relief on input power cable.
Install and connect grounding conductor and input conductors in conduit or equivalent to deenergized
line disconnect device.
1
3
Be sure grounding conductor goes
to an earth ground.
Reinstall side panel.
Tools Needed:
7/16 in
7
5
3/8 in
3/16 in
input_2 3/96 - Ref. ST-144 221 / Ref. ST-801 883-B
OM-2221 Page 18
Return To Table Of Contents
3-16. Matching Primary Lines L1, L2, And L3 When Using Multiple Units
Set on AC Volts Scale
Turn Off welding power
source and disconnect input
power before opening access door.
This test must be performed on the
units that will be interconnected using the synchronizing terminal strip
TE4. This refers to the multiple unit
hook-ups shown in Sections 4-2,
4-3, and 4-5.
Meter Polarity Does Not Matter
Power On both units. Using an ac
voltmeter, measure the voltage between terminal A of terminal strip
TE3 on both units as shown.
A
B
C
D
E
G
I
J
K
L
N
P
If the measured voltage is 0 (zero)
volts, the primary lines are properly
phased.
If the measured voltage is 48 volts,
swap the input conductor connections to L1 and L3 on the primary input contactor of unit B.
A
B
C
D
E
G
I
J
K
L
N
P
Terminal Strip
TE3
If the measured voltage is 42 volts,
swap L1 and L2 on the primary input
contactor of unit B. The meter will
then read either 48 volts or 24 volts.
If the meter reads 48 volts, swap L1
and L3. If the meter reads 24 volts,
swap L2 and L3.
Terminal Strip
TE3
Unit B
(Slave)
Unit A
(Master)
If the measured voltage is 24 volts,
swap L1 and L2 on the primary input
contactor of unit B. The meter will
then read either 0 (zero) volts or 42
volts. If the meter reads 0 volts, the
primary lines are properly phased.
If the meter reads 42 volts, swap L1
and L2 again, and swap L2 and L3.
When the second (slave) unit’s primary line phase sequences are
matched with the first (master) unit,
test primary phasing between third
unit (if applicable) and second unit.
Always test and correct phasing
between following unit and unit previous to it.
L1
L2
L3
Input Contactor
Ref. ST-801 882-A / Ref. 801 883-B
Return To Table Of Contents
OM-2221 Page 19
SECTION 4 − MAKING WELD OUTPUT CONNECTIONS
4-1. Work And Electrode Cable Connections For Single DC or AC Arcs
If there are any questions regarding
this procedure, contact the factory before connecting units.
Turn Off welding power
source and disconnect input
power before opening access door.
ELECTRIC SHOCK can kill.
For dc electrode positive:
Do not touch live electrical parts.
Connect the proper size and number of weld output cables (see Section 3-8) to one of the welding power
source electrode terminals.
Turn off welding power sources and disconnect input power before making any weld output connections.
See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
Do not handle or come in contact with two live electrodes at the same time.
UNDERSIZED WELD CABLES can cause fire.
Connect the proper size and number of ground cables to one of the
welding power source work terminals.
For dc electrode negative:
Work cable or electrode cable must be able to carry the weld output of the individual welding power
source (see Section 3-8).
Do not exceed duty cycle of welding power sources.
Connect the proper size and number of weld output cables (see Section 3-8) to one of the welding power
source work terminals.
Connect the proper size and number of ground cables to one of the
welding power source electrode
terminals.
For ac output:
To Electrode
To Electrode
Connect the proper size and number of weld output cables (see Section 3-8) to one of the welding power
source electrode terminals.
Connect the proper size and number of ground cables to one of the
welding power source work terminals.
To Work
To Work
Connections For
DC Electrode Positive
Or AC Output
Connections For
DC Electrode
Negative Output
High weld output current hazard! Remove all metal jewelry, such as
rings and watches, and be careful with tools near output terminals.
High current can cause severe burns from hot metal if touched to
output terminals and unit is On. ALWAYS turn Off welding power
sources and disconnect input power BEFORE making weld output
connections.
ST-801 882-A
OM-2221 Page 20
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4-2. Using Multiple Units: DC Lead Arc, One or More AC Trailing Arcs
With Separate Electrodes
If there are any questions regarding
this procedure, contact the factory before connecting units.
ELECTRIC SHOCK can kill.
Turn Off welding power
source and disconnect input
power before opening access door.
To use a dc electrode positive lead
arc with one or more trailing ac arcs,
make connections as shown.
Do not touch live electrical parts.
Turn off welding power sources and disconnect input power before making any weld output connections.
See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
Do not handle or come in contact with two live electrodes at the same time.
UNDERSIZED WELD CABLES can cause fire.
Work cable or electrode cable must be able to carry the weld output of the individual welding power
source (see Section 3-8).
Securely cover common connections with proper insulating material as shown in detail below.
When running more than one ac
trailing arc, set up the ac units according to Section 4-6 or 4-7, as applicable.
When using multiple arcs in
parallel, be sure to follow
unit setup instructions carefully. Severe damage to units
may occur if units are not
correctly connected for parallel operation.
Do not exceed duty cycle of welding power sources.
To
DC Output Electrode #1
To AC
Output
Electrode #2
To AC
Output
Electrode #3
To Next AC
Unit
DC Output Unit
Connections
First AC Output Unit
Connections
To Work
To Work
Second AC Output Unit
(And Following Units)
Connections
To Work
Shielded Cable To
Terminal Strip TE4
High weld output current hazard! Remove all metal jewelry, such as rings
and watches, and be careful with tools near output terminals. High current can cause severe burns from hot metal if touched to output terminals
and unit is On. ALWAYS turn Off welding power sources and disconnect
input power BEFORE making weld output connections.
ST-801 882-A
Return To Table Of Contents
OM-2221 Page 21
4-3. Using Multiple Units: Two or More AC Arcs With Separate Electrodes
Turn Off welding power
source and disconnect input
power before opening access door.
If there are any questions regarding
this procedure, contact the factory before connecting units.
ELECTRIC SHOCK can kill.
To use two or more ac arcs with
separate electrodes, make connections as shown.
Do not touch live electrical parts.
Turn off welding power sources and disconnect input power before making any weld output connections.
Set up ac output units according to
Section 4-6 or 4-7, as applicable.
See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
When using multiple arcs in
parallel, be sure to follow
unit setup instructions carefully. Severe damage to units
may occur if units are not
correctly connected for parallel operation.
Do not handle or come in contact with two live electrodes at the same time.
UNDERSIZED WELD CABLES can cause fire.
Work cable or electrode cable must be able to carry the weld output of the individual welding power
source (see Section 3-8).
Securely cover common connections with proper insulating material as shown in detail below.
Do not exceed duty cycle of welding power sources.
To AC Output
Electrode #1
To AC Output
Electrode #2
To Next AC Unit
First Unit
Connections
To Work
Second Unit (And
Following Units)
Connections
To Work
Shielded Cable To
Terminal Strip TE4
High weld output current hazard! Remove all metal jewelry, such as rings
and watches, and be careful with tools near output terminals. High current can cause severe burns from hot metal if touched to output terminals
and unit is On. ALWAYS turn Off welding power sources and disconnect
input power BEFORE making weld output connections.
ST-801 882-A
OM-2221 Page 22
Return To Table Of Contents
4-4. Using Multiple Units: Parallel DC Output Connections
Turn Off welding power
source and disconnect input
power before opening access door.
If there are any questions regarding
this procedure, contact the factory before connecting units.
ELECTRIC SHOCK can kill.
To use multiple units in parallel,
make connections as shown.
Do not touch live electrical parts.
All units must be set up for dc output
according to Section 3-9. Do not parallel dc output units with ac output
units.
Turn off welding power sources and disconnect input power before making any weld output connections.
See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
When connecting two or more
Do not handle or come in contact with two live electrodes at the same time.
units in parallel, do not use
more than one unit in CV mode.
All units can be operated in CC
mode if a voltage-sensing wire
feed system is used. If
constant voltage output is required, operate only one unit in
the CV mode and put the remaining units in the CC mode
with their output set to a percentage of total welding output
divided by the total number of
units used.
UNDERSIZED WELD CABLES can cause fire.
Use separate cables from each welding power source. The work or electrode cable from each
welding power source must be able to carry the output of the individual welding power source (see
Section 3-8).
Do not exceed duty cycle of welding power sources.
Set Amperage/Voltage Adjustment controls on all paralleled units for the same output.
To
Electrode
To
Electrode
When using multiple arcs in
parallel, be sure to follow
unit setup instructions carefully. Severe damage to units
may occur if units are not
correctly connected for parallel operation.
To Work
To Work
First Unit
Connections
Second Unit (And
Following Units)
Connections
High weld output current hazard! Remove all metal jewelry, such as rings
and watches, and be careful with tools near output terminals. High current can cause severe burns from hot metal if touched to output terminals
and unit is On. ALWAYS turn Off welding power sources and disconnect
input power BEFORE making weld output connections.
ST-801 882-A
Return To Table Of Contents
OM-2221 Page 23
4-5. Using Multiple Units: Parallel AC Output Connections
If there are any questions regarding
this procedure, contact the factory before connecting units.
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Turn off welding power sources and disconnect input power before making any weld output connections.
See ANSI Z49.1 and OSHA Title 29, Chapter XVII, Part 1910, Subpart Q (addresses at beginning of manual).
Turn Off welding power
source and disconnect input
power before opening access door.
Always test for correct phasing before paralleling ac outputs according to Section
4-9.
To use multiple units in parallel,
make connections as shown.
UNDERSIZED WELD CABLES can cause fire.
All units must be set up for ac output
according to Section 3-9. Do not
parallel dc output units with ac output units.
Use separate cables from each welding power source. The work or electrode cable from each
welding power source must be able to carry the output of the individual welding power source (see
Section 3-8).
The welding power source outputs
must be synchronized according to
Section 4-6.
Do not exceed duty cycle of welding power sources.
When connecting two or more
Do not handle or come in contact with two live electrodes at the same time.
Set Amperage/Voltage Adjustment controls on all paralleled units for the same output.
To
Electrode
To
Electrode
units in parallel, do not use
more than one unit in CV mode.
All units can be operated in CC
mode if a voltage-sensing wire
feed system is used. If
constant voltage output is required, operate only one unit in
the CV mode and put the remaining units in the CC mode
with their output set to a percentage of total welding output
divided by the total number of
units used.
When using multiple arcs in
parallel, be sure to follow
unit setup instructions carefully. Severe damage to units
may occur if units are not
correctly connected for parallel operation.
To Next AC Unit
To Work
To Work
First Unit
Connections
Second Unit (And
Following Units)
Connections
Shielded Cable To
Terminal Strip TE4
(See Section 4-6)
High weld output current hazard! Remove all metal jewelry, such as rings
and watches, and be careful with tools near output terminals. High current can cause severe burns from hot metal if touched to output terminals
and unit is On. ALWAYS turn Off welding power sources and disconnect
input power BEFORE making weld output connections.
ST-801 882-A
OM-2221 Page 24
Return To Table Of Contents
4-6. Synchronizing Outputs For Parallel AC Arcs
If there are any questions regarding this procedure,
contact the factory before connecting units.
Turn Off welding power
source and disconnect input
power before opening access door.
1
1
A
B
C
D
E
Do not disturb factory connections to terminal strip TE4.
Ensure that primary input
power conductors are connected to each unit in the
same sequence (L1 to L1, L2
to L2, and L3 to L3). See Section 3-15 for information on
connecting input power. See
Section 3-16 for information
on testing for proper primary
phase sequence.
All synchronized units must be set up for ac output according to Section 3-9. Do not mix dc and ac output units.
Always test for correct phasing before paralleling ac outputs according to Section
4-9.
Use two-conductor (12 to 20 gauge), with uninsulated ground,
2
shielded cable to make TE4 connections. Connect ground to
terminal C on TE4.
1
3
Lead Being Connected To
TE4
Securing Screw
Strip 3/8 in (10 mm) insulation off
end of lead, insert end into proper
location on TE4, and tighten applicable securing screw.
3/8 in
(10 mm)
2
Terminal Strip TE4
This procedure allows the ac outputs of two or more units to be synchronized so the waveforms
match. To synchronize outputs,
make connections between terminal strip TE4 on each ac output unit
as shown in illustration.
3
Close and secure access door.
Make
certain control board
PC1 is set for synchronized
parallel ac arcs (see Section
4-8).
Connections from first to second
welding power source:
terminal A to terminal E,
terminal B to terminal B,
terminal C to terminal C
A
B
C
D
E
TE4 on first
welding power
source
Connections from second to third
welding power source:
terminal A to terminal E,
terminal B to terminal B,
terminal C to terminal C
A
B
C
D
E
A
B
C
D
E
TE4 on second
welding power
source
TE4 on third
welding power
source
Connections from third to fourth
welding power source:
terminal A to terminal E,
terminal B to terminal B,
terminal C to terminal C
When using multiple arcs in
parallel, be sure to follow
unit setup instructions carefully. Severe damage to units
may occur if units are not
correctly connected for parallel operation.
Repeat same connection sequence on following
welding power sources
Terminal Strip TE4 Connections For Operating Multiple AC Units In Parallel
Tools
Needed:
ST-801 882-A
Return To Table Of Contents
OM-2221 Page 25
4-7. Using Non-Parallel AC Arcs Terminal Strip TE4 Connections
If there are any questions regarding this procedure,
contact the factory before connecting units.
1
Tools Needed:
Turn Off welding power
source and disconnect input
power before opening access door.
All units must be set up for ac
output according to Section
3-9. Do not parallel dc output
units with ac output units.
A
B
C
D
E
DC output units do not require synchronization with
AC output units.
1
Terminal Strip TE4
This procedure allows the ac output
waveforms of two or more units to
have a phase shift. Make connections between terminal strip TE4 on
applicable ac output units as shown
in illustration.
Phase Shift
Do not disturb factory connections to terminal strip TE4.
Waveform 1
Ensure that primary input
power conductors are connected to each unit in the
same sequence (L1 to L1, L2
to L2, and L3 to L3). See Section 3-15 for information on
connecting input power. See
Section 3-16 for information
on testing for proper primary
phase sequence.
Waveform 2
AC Waveforms
Use two-conductor (12 to 20 gauge), with uninsulated ground,
2
shielded cable to make TE4 connections. Connect ground to
terminal C on TE4.
1
Strip 3/8 in (10 mm) insulation off
end of lead, insert end into proper
location on TE4, and tighten applicable securing screw.
3/8 in
(10 mm)
2
3
Lead Being Connected To
TE4
Securing Screw
Close and secure access door.
3
Connect plug as shown in Section 4-8.
Connections from first to second
welding power source:
terminal A to terminal E,
terminal C to terminal C
A
B
C
D
E
Connections from second to third
welding power source:
terminal A to terminal E,
terminal C to terminal C
A
B
C
D
E
TE4 on first welding
power source
Connections from third to fourth
welding power source:
terminal A to terminal E,
terminal C to terminal C
A
B
C
D
E
TE4 on second welding
power source
TE4 on third welding
power source
Repeat same connection sequence
on following welding power sources
Terminal Strip TE4 Connections For Running Multiple, Non-Parallel AC Arcs
OM-2221 Page 26
Return To Table Of Contents
Ref. 801 882-A
4-8. Control Board PC1 Connections For Non-Parallel AC Arcs Or Parallel Synchronized
AC Arcs
Turn Off welding power
source and disconnect input
power before following this
procedure.
Remove top cover.
If there are any questions regarding this procedure,
contact the factory before connecting units.
1
2
3
2
Front Panel
Circuit Card Cover
Control Board PC1
Locate and remove circuit card
cover mounted on upper right inside of front panel. PC1 is mounted
on inside of control panel where circuit card cover was removed.
3
1
4
Receptacle RC4
PC1 arrives from the factory with a
synchronized ac arc (0°) plug.
With 60
Hz input power, the
output of this unit is 10 Hz. With
50 Hz input, the output is 8.33
Hz.
To operate the unit with ac arcs that
have a variable balance shift, disconnect the synchronized ac arc
(0°) plug and connect the appropriate supplied variable balance plug.
To resume operation with synchronized ac arcs, disconnect the variable balance plug and connect the
synchronized ac arc (0°) plug.
Plugs are labeled accordingly.
Always
keep disconnected
plug for future use.
3
4
PC1 Viewed From Rear Of Unit
Reinstall circuit card cover and top
cover.
Tools Needed:
3/8 in
Ref. SD-801 982-A
Return To Table Of Contents
OM-2221 Page 27
4-9. Testing AC Output Units For Correct Phasing Prior to Parallel Operation
If there are any questions regarding this procedure,
contact the factory before connecting units.
Turn Off welding power
sources and disconnect input power before opening
access door.
If units are not phased correctly, the welding power
sources may be damaged.
Set on AC Volts Scale
Meter Polarity Does Not Matter
To Separate Electrode
(Electrically Isolated From
All Other Electrodes)
To Separate Electrode
(Electrically Isolated From
All Other Electrodes)
Open-circuit voltage will be
present on all electrodes
during this check. If the machines are not phased correctly, the voltage between
electrodes may equal two
times open-circuit voltage
(135 - 145 volts ac). Have only
qualified persons do this
testing.
Be sure synchronizing connections
in Section 4-6 have been made before performing this procedure.
Make connections as shown in illustration. Connect ac voltmeter
between electrode connected to
first (master) unit and electrode
connected to second (slave) unit.
Power On both units and place both
output control switches in On position. When the units are properly
phased, the voltmeter will read
less than one volt ac.
If the meter reads more than one
volt ac, the unit’s primary lines are
not matched in the proper phase
sequence (see Section 3-16).
After performing the test in Section
3-16, retest the units for phasing.
When the second (slave) unit is in
phase with the first (master) unit,
test phasing between third unit (if
applicable) and second unit. Always test and correct phasing between following unit and the unit
previous to it (check fourth unit
against third unit, fifth unit against
fourth unit, etc.).
To Next AC Unit
To Work
To Work
First (Master) Unit
Connections
Second (Slave) Unit
(And Following Units)
Connections
After setting units up for correct
synchronizing, connect units according to section covering desired
multiple unit use (see Sections 4-2,
4-3, and 4-5).
Shielded Cable To
Terminal Strip TE4
(See Section 4-6)
ST-801 882-A
OM-2221 Page 28
Return To Table Of Contents
SECTION 5 − OPERATION
5-1. Front Panel Controls (Non-CE Models)
1 Output Control Switch
For weld output, place switch in On position.
For remote control of output, make connections to terminal strip TE3 or Remote 14 receptacle (see Section 3-10) and place switch
in Remote position.
2 A/V (Amperage/Voltage) Control Switch
For front panel control, place switch in Panel
position and use the A/V Adjust control.
Turn Off power before connecting remote device.
For remote control, connect remote device to
terminal strip TE3 or Remote 14 receptacle,
and place switch in Remote position. Remote
control provides full range of unit output regardless of A/V Adjust control setting
5
3
Pilot Light
4
Power Push Button Switch
Use control to select weld voltage or amperage. Control may be adjusted while welding.
Numbers on scale are for reference only.
The
fan motor is thermostatically
controlled and only runs when cooling is
needed.
1
2
High Temperature Shutdown Light
Lights if welding power source overheats.
6
7
A/V (Amperage/Voltage) Adjustment
Control
CC/CV Switch (Mounted Inside Access
Area)
Place switch in desired position.
3
4
6
5
CC
CV
7
Turn Off welding power
source before opening access door to change switch
position.
Ref. ST-175 086 / Ref. ST-801 882-A
Return To Table Of Contents
OM-2221 Page 29
5-2. Front Panel Controls (CE Models)
1 Output Control Switch
For weld output, place switch in On position.
For remote control of output, make connections to terminal strip TE3 or Remote 14 receptacle (see Section 3-10) and place switch
in Remote position.
2 A/V (Amperage/Voltage) Control Switch
For front panel control, place switch in Panel
position and use the A/V Adjust control.
Turn Off power before connecting remote device.
For remote control, connect remote device to
terminal strip TE3 or Remote 14 receptacle,
and place switch in Remote position. Remote
control provides full range of unit output regardless of A/V Adjust control setting
5
3
Pilot Light
4
Power Push Button Switch
Use control to select weld voltage or amperage. Control may be adjusted while welding.
Numbers on scale are for reference only.
6
The
7
fan motor is thermostatically
controlled and only runs when cooling is
needed.
2
1
High Temperature Shutdown Light
Lights if welding power source overheats.
A/V (Amperage/Voltage) Adjustment
Control
CC/CV Switch (Mounted Inside Access
Area)
Place switch in desired position.
3
4
6
5
CC
CV
7
Turn Off welding power
source before opening access door to change switch
position.
Ref. ST-175 086 / Ref. ST-801 882-A
OM-2221 Page 30
Return To Table Of Contents
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
Maintain more often
Disconnect input power
before maintaining.
during severe conditions.
3 Months
Replace damaged
or unreadable
labels.
Replace
cracked
torch body.
Repair or
replace
cracked cables.
Repair or
replace
cracked cables and
cords.
Clean and
tighten
weld
terminals.
6 Months
Blow out inside.
6-2. Fuses F1 And F2
Turn Off welding power
source and disconnect input
power before checking fuse.
1
2
Fuses F1 and F2 protect the 115
volt ac winding of transformer T2. If
fuse F1 or F2 opens, the welding
power source shuts down.
Remove top cover from unit to access fuses.
1
Fuse F1
Check F1 and replace if needed,
using a fuse of the same rating.
2
Fuse F2
Check F2 and replace if needed,
using a fuse of the same rating.
Use proper tool when removing
fuses.
Reinstall top cover.
Rear of Unit
Tools Needed:
3/8 in
Ref. ST-801 883-B
Return To Table Of Contents
OM-2221 Page 31
6-3. Access Area Circuit Breakers
Turn Off welding power
source and disconnect input
power before checking circuit breakers.
1
Circuit Breaker CB2
CB2 protects the 24 VAC portion of
terminal strip TE3 and the Remote
14 receptacle.
2
Circuit Breaker CB3
CB3 protects the 42 VAC portion of
terminal strip TE3.
1
Press button to reset breaker.
2
CB2
CB3
Ref. ST-175 086 / ST-801 882-A
6-4. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 3-15).
Check fuses F1 and F2 and replace if necessary (see Section 6-2).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-15).
Check for proper input power connections (see Section 3-15).
No weld output; pilot light On.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-2).
Have Factory Authorized Service Agent check control board PC1.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 3-8).
Clean and tighten all weld connections.
When using multiple units, make sure all units connected with terminal strip TE4 are turned on.
Have Factory Authorized Service Agent check control board PC1.
No 115 volts ac output at duplex
receptacle, terminal strip TE3, and Remote 14 receptacle.
Reset circuit breaker CB1 (see Section 3-12).
No 230 volts ac output at duplex recep- Reset circuit breaker CB4 (see Section 3-13).
tacle.
No 24 volts ac output at terminal strip
TE3 and Remote 14 receptacle.
Reset circuit breaker CB2 (see Section 6-3).
No 42 volts ac output at terminal strip
TE3.
Reset circuit breaker CB3 (see Section 6-3).
OM-2221 Page 32
Return To Table Of Contents
Notes
Return To Table Of Contents
OM-2221 Page 33
SECTION 7 − ELECTRICAL DIAGRAMS
213 402-B
Figure 7.1. Circuit Diagram For 460 And 575 VAC Input Models
OM-2221 Page 34
Return To Table Of Contents
213 403-B
Figure 7.2. Circuit Diagram For 400 VAC Input Models
Return To Table Of Contents
OM-2221 Page 35
12
26
27
32
1
2
3
4
25
1
24
31
28
5
29
6
9
27
30
10
11
13
7
8
20
23
14
18
17
16
19
5
21
22
15
SECTION 8 − PARTS LIST
Hardware is common and
not available unless listed.
801 981-A
Figure 8-1. Main Assembly
OM-2221 Page 36
Return To Table Of Contents
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-1. Main Assembly
. . 1 . . . . . . . . . . . 071 624 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 2 . . . . . . . . . . +070 555 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . 217 136 . . LABEL,warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . 217 862 . . LABEL,warning electric shock and ac/dc lkg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . 184 340 . . CHANNEL, upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 6 . . . . . . . . . . . 188 403 . . BRACKET, mtg lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 7 . . F1,F2 . *012 639 . . FUSE, crtg 6A 600 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 8 . . . . . . . . . . . 070 404 . . FUSE, holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 9 . . . . W . . . 099 044 . . CONTACTOR, size 3-1/2 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . W1,2 . . 048 731 . . INTERLOCK, cntor No. size 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 10 . . C1-3 . . 219 496 . . CAPACITOR (non CE models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 10 . . C1-3 . . 194 066 . . CAPACITOR (CE models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 11 . . . . . . . . . . 184 349 . . BRACKET, mtg contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . HD1 . . 148 417 . . TRANSDUCER, current 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG1 . . 130 204 . . CONNECTOR & SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . TE2 . . . 213 419 . . TERMINAL ASSEMBLY, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . 184 359 . . BRACKET, mtg terminal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 15 . . . . . . . . . . . Fig 8-3 . . REAR PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . 217 860 . . LABEL,warning electric shock and input pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . Z1 . . . 184 350 . . STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . T1 . . . 184 406 . . TRANSFORMER, pwr main (460 model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . T1 . . . 188 222 . . TRANSFORMER, pwr main (575 model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . T1 . . . 185 360 . . TRANSFORMER, pwr main (400 50/60hz model) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . TP2 . . . 163 266 . . THERMOSTAT, NC in trans. 150° C overload . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . TP1 . . . 168 891 . . THERMOSTAT, NC in trans. 80° C fan on demand . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . 184 344 . . STOP, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 026 627 . . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . T2 . . . 094 237 . . TRANSFORMER, kva 1/2 115-230/460 (460 model) . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . T2 . . . 096 145 . . TRANSFORMER, kva 1/2 115-230/575 (575 model) . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . T2 . . . 185 359 . . TRANSFORMER, kva 1/2 115-220/400 (400 50/60hz model) . . . . . . . . . . . . . 1
. . 21 . . . . . . . . . . 184 342 . . LIFT, eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . 184 341 . . BAR, cross lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 23 . . . . . . . . . . 184 345 . . BRACKET, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . SR1 . . 213 441 . . RECTIFIER, scr main (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 25 . . . . . . . . . . 026 947 . . . STAND-OFF, insul .250-20 x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 26 . . . . . . . . . . 185 206 . . . STRIP, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 27 . . . . . . . . . . 196 496 . . . CLAMP, thyristor rectifier 4.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 28 SCR1-6 . 148 091 . . . THYRISTOR, scr 865 A 300 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 29 . . . . . . . . . . 185 207 . . . STRIP, spacing heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . 082 852 . . . BUS BAR, output rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 30 . C11-16/
. . . . . . . R11-16 . 185 183 . . . CAPACITOR/RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . TP3, 4, 5
. . . . . . . 6, 7, 8 . . 192 732 . . . THERMOSTAT, NC open 203° F in SR1 overload . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . TP9, 10,
11, 12, 13, 14 . . . 168 894 . . . THERMOSTAT, NC open 125° F in SR1 fan on demand . . . . . . . . . . . . . . . . 6
. . 31 . . . . . . . . . . 184 343 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . . . . . . . . . Fig 8-2 . . FRONT PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Return To Table Of Contents
OM-2221 Page 37
25
27
20
26
24
23
22
15
21
39
not available unless listed.
37
36
2
35
34
39
33
32
3
31
4
5
6
38
7
8
9
30
11
29
12
13
28
15
16
14
17
18
5
19
Hardware is common and
1
SD-801 982-C
Figure 8-2. Front Panel Assembly
OM-2221 Page 38
Return To Table Of Contents
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-2. Front Panel Assembly (Figure 8-1 Item 32)
. . . 1 . . . . . . . . . . . . . 038 805 . . COVER, receptacle weatherproof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . +187 759 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . RC1 . . . 604 176 . . RECEPTACLE, str dx grd 2P3W 15A 125V (460 & 575 models) . . . . . . .
. . . 4 . . . . RC1 . . . 176 355 . . RECEPTACLE, str 2P3W 16A 220V (400 50/60hz model) . . . . . . . . . . . .
. . . 5 . . . CB1-3 . . 053 283 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC (460 & 575 models) . .
. . . 5 . . . CB1-4 . . 053 283 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC (400 50/60hz model) .
. . . 6 . . . . S1,2 . . . . 011 609 . . SWITCH, tglSPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . R5 . . . . 030 109 . . POTENTIOMETER, cp std slot 1/T 2W 5K linear . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . PB1 . . . . 011 636 . . SWITCH, pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . PC1 . . . 191 268 . . CIRCUIT CARD, control (460 & 575 models) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . PC1 . . . 192 444 . . CIRCUIT CARD, control (400 50/60hz model) . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG11 . . 163 467 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG12 . . 152 249 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . PLG13 . . 158 720 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . CR1 . . . 039 498 . . RELAY, encl 120 VAC 3PDT 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . C9,10 . . 130 710 . . CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . R3,4 . . . 136 076 . . RESISTOR, ww fxd 30W 200 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . 059 567 . . TERMINAL, pwr output (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . 601 841 . . . . NUT, brs hex jam .625-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . 038 032 . . . . BUS BAR, neg and pos sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 208 935 . . . . TERMINAL, hammer on 3/0 − 4/0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . 601 842 . . . . NUT, brs hex full .625-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . 059 566 . . . . TERMINAL BOARD, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . 038 909 . . . . STUD, brs .625-11 x 3.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . 602 249 . . . . WASHER, flat stl SAE .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . 602 219 . . . . WASHER, lock stl external tooth .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . 059 983 . . BUS BAR, jumper secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . 188 514 . . BRACKET, mtg term assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . 110 375 . . STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . PC2 . . . 148 030 . . CIRCUIT CARD, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . RC7 . . . 134 735 . . CONNECTOR, circ ms/cpc 14 skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . S3 . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . TE4 . . . 192 357 . . BLOCK, term 40A 5P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . TE3 . . . 188 719 . . BLOCK, term 40A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . 098 691 . . STAND-OFF, No. 6-32 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . 605 583 . . CATCH, spr loaded door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . 217 861 . . LABEL,warning electric shock can kill etc . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . 027 631 . . HOUSING, light ind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . PL1,2 . . . 027 629 . . BULB, incand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . 182 704 . . LENS, light ind white . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . 176 246 . . LENS, light ind amber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . 097 924 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . 209 319 . . KIT, variable balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . . . . . 117 860 . . BLANK, snap−in nyl .187 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
3
4
2
1
1
1
1
1
1
1
1
2
2
1
16
4
1
8
2
8
8
8
2
1
3
1
1
1
1
1
4
1
1
2
2
1
1
1
1
4
+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.
Return To Table Of Contents
OM-2221 Page 39
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-3. Rear Panel Assembly (Figure 8-1 Item 15)
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
. . . . CR2 . . . 059 266
. . . . . . . . . . . . . 209 477
. . . . R1,2 . . . 097 459
. . . . . . . . . . . . . 032 616
. . . . . . . . . . . . +070 558
. . . . . . . . . . . . . 183 167
. . . . . . . . . . . . . 102 207
. . . . . FM . . . . 032 605
..
..
..
..
..
..
..
..
RELAY, encl 120 VAC DPDT 10A/120 VAC . . . . . . . . . . . . . . . . . . . . . . . . .
WINDTUNNEL, 20in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, ww fxd 375W 20 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLADE, fan 20.000 3wg 21deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR, clamp cable 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATE, adapter power cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR, cap perm sp 1/4hp 230 VAC 1625rpm . . . . . . . . . . . . . . . . . . . . .
3
1
1
2
1
1
1
1
1
5
4
2
1
6
7
8
Hardware is common and
not available unless listed.
SD-801 983
Figure 8-3. Rear Panel Assembly
+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-2221 Page 40
Return To Table Of Contents
Notes
Return To Table Of Contents
OM-2221 Page 41
Notes
OM-2221 Page 42
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
 2004 Miller Electric Mfg. Co.
1/03
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