Miller | LC206711 | Owner Manual | Miller SUMMIT ARC 1000 User manual

Miller SUMMIT ARC 1000 User manual
OM-2221
186 183F
August 2002
Processes
Submerged (SAW) Welding
Description
Arc Welding Power Source

Summit Arc 1000
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 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
OM-2221
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. 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 With A 60° Phase Shift - Terminal Strip TE4 Connections . . . .
3-8. Control Board PC1 Connections For Non-Parallel AC Arcs
With 60° Phase Shift Or Parallel Synchronized (0° Phase Shift) 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 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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
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
MILLER Europe S.r.l.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
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.
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 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.
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.
OM-2221 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
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).
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.
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.
HOT PARTS can cause severe burns.
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.
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
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
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.
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. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-2221 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-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.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de
sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimentation électrique.
Arrêter les convertisseurs, débrancher le courant électrique, et décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer et mettre à la terre correctement cet 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.
En effectuant les raccordements d’entrée fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas 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 provenant d’une autre machine.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer
les fumées.
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un
surveillant dûment formé de se tenir à proximité. Des fumées et des
gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
rayons de l’arc peuvent réagir en présence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien
ventilé, et si nécessaire, en portant un respirateur à alimentation
d’air. Les revêtements et tous les métaux renfermant ces éléments
peuvent dégager des fumées toxiques en cas de soudage.
OM-2221 Page 5
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées
pendant le soudage.
Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être
projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
Se protéger et d’autres personnes de la projection d’étincelles et de
métal chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur
des substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7
m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par
des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-2221 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.
Ne pas toucher des parties chaudes à mains nues
Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
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.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procédé de soudage, les
manipuler avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, 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 placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une
bouteille.
Ne jamais souder une bouteille pressurisée – risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
Maintenir le chapeau de protection 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 CGA énumérées dans les normes de sécurité.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables.
Rester à l’écart des organes mobiles comme le
ventilateur.
Maintenir fermés et fixement en place 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 dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
Utiliser un engin d’une capacité appropriée pour
soulever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Prévoir une période de refroidissement, respecter le cycle opératoire nominal.
Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil
de soudage.
Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de radio–navigation et de communication, les services
de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
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
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-2221 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – 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.
2-1. 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)
575 V
(60 Hz)
KVA
KW
143
(3*)
124
(3*)
100
(3*)
98
(2.37*)
53
(0.95*)
*While idling
2-2. 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
OM-2221 Page 9
2-3. 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
DC Output
AC Output
va_curve1 4/95 – SA-189 242 / SA-189 240 / SA-189 243 / SA-189 241
OM-2221 Page 10
2-4. 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.
2-5. 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)
OM-2221 Page 11
2-6. Manufacturer’s Rating Label For CE Products
2-7. 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
2-8. 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
OM-2221 Page 13
2-9. 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
2-10. 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
2-11. 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
2-10
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
OM-2221 Page 15
2-12. 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 2-10).
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
2-13. 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
2-14. Electrical Service Guide
Three-Phase,
50/60 Hz
Input Voltage
Three-Phase, 60 Hz
380/400/415
460
575
Input Amperes At Rated Output
143
124
100
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
200
175
150
Min Input Conductor Size In AWG/Kcmil
1/0
1
2
382 (116)
417 (127)
575 (175)
6
6
6
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1997 National Electrical Code (NEC).
S-0092-J
2-15. 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 2-16 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 2-14.
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.
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 17
2-16. 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 3-2,
3-3, and 3-5.
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
OM-2221 Page 18
SECTION 3 – MAKING WELD OUTPUT CONNECTIONS
3-1. 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 2-8) 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 2-8).
Do not exceed duty cycle of welding power sources.
Connect the proper size and number of weld output cables (see Section 2-8) 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 2-8) 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 19
3-2. 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 2-8).
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 3-6 or 3-7, 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
OM-2221 Page 20
3-3. 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 3-6 or 3-7, 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 2-8).
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 21
3-4. 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 2-9. 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 2-8).
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
OM-2221 Page 22
3-5. 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
3-9.
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 2-9. 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 2-8).
The welding power source outputs
must be synchronized according to
Section 3-6.
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 3-6)
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 23
3-6. 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 2-15 for information on
connecting input power. See
Section 2-16 for information
on testing for proper primary
phase sequence.
All synchronized units must be set up for ac output according to Section 2-9. Do not mix dc and ac output units.
Always test for correct phasing before paralleling ac outputs according to Section
3-9.
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
3-8).
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
TE4 on second
welding power
source
A
B
C
D
E
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:
OM-2221 Page 24
ST-801 882-A
3-7. 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
2-9. 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 60° phase shift. Make connections between terminal strip
TE4 on applicable ac output units
as shown in illustration.
60° 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 2-15 for information on
connecting input power. See
Section 2-16 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 3-8.
Connections from first to second
welding power source:
terminal A to terminal E,
terminal B to terminal D,
terminal C to terminal C
A
B
C
D
E
Connections from second to third
welding power source:
terminal A to terminal E,
terminal B to terminal D,
terminal C to terminal C
A
B
C
D
E
TE4 on first welding
power source
TE4 on second welding
power source
Connections from third to fourth
welding power source:
terminal A to terminal E,
terminal B to terminal D,
terminal C to terminal C
A
B
C
D
E
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
Ref. 801 882-A
OM-2221 Page 25
3-8. 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
OM-2221 Page 26
3-9. 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 3-6 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 2-16).
After performing the test in Section
2-16, 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 3-2,
3-3, and 3-5).
Shielded Cable To
Terminal Strip TE4
(See Section 3-6)
ST-801 882-A
OM-2221 Page 27
SECTION 4 – OPERATION
4-1. 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 2-10) 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
OM-2221 Page 28
4-2. 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 2-10) 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 29
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING
5-1. 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.
5-2. 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
OM-2221 Page 30
5-3. 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
5-4. Troubleshooting
Trouble
No weld output; unit completely inoperative.
Remedy
Place line disconnect switch in On position (see Section 2-15).
Check fuses F1 and F2 and replace if necessary (see Section 5-2).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 2-15).
Check for proper input power connections (see Section 2-15).
No weld output; pilot light On.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 2-2).
Have Factory Authorized Service Agent check control board PC1.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 2-8).
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 2-12).
No 230 volts ac output at duplex recep- Reset circuit breaker CB4 (see Section 2-13).
tacle.
No 24 volts ac output at terminal strip
TE3 and Remote 14 receptacle.
Reset circuit breaker CB2 (see Section 5-3).
No 42 volts ac output at terminal strip
TE3.
Reset circuit breaker CB3 (see Section 5-3).
OM-2221 Page 31
SECTION 6 – ELECTRICAL DIAGRAMS
193 775-C
Figure 6-1. Circuit Diagram For 460 And 575 VAC Input Models
OM-2221 Page 32
188 378-H
Figure 6-2. Circuit Diagram For 400 VAC Input Models
OM-2221 Page 33
12
26
27
(Fig.7–2) –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–(Fig. 7–3)
SECTION 7 – PARTS LIST
Hardware is common and
not available unless listed.
801 981-A
Figure 7-1. Main Assembly
OM-2221 Page 34
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Main Assembly
. . 1 . . . . . . . . . . . 071 624 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 2 . . . . . . . . . . +070 555 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . 185 860 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . 194 066 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . 11 . . . . . . . . . . 184 349 . . BRACKET, mtg contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . . HD1 . . 148 417 . . TRANSDUCER, current 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG1 . . 130 204 . . CONNECTOR & SOCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . TE2 . . . 187 739 . . TERMINAL ASSEMBLY, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . . . . . . . . . 184 359 . . BRACKET, mtg terminal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 15 . . . . . . . . . . . Fig 7-3 . . REAR PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 16 . . . . . . . . . . 185 856 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
. . . . . . . . TP3 . . . 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 . . 184 357 . . 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
. . . . . . . . TP1 . . . 012 786 . . . THERMOSTAT, NC open 165° F in SR1 overload . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . TP4 . . . 168 894 . . . THERMOSTAT, NC open 125° F in SR1 fan on demand . . . . . . . . . . . . . . . . 1
. . 31 . . . . . . . . . . 184 343 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 32 . . . . . . . . . . . Fig 7-2 . . 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.
OM-2221 Page 35
25
17
18
5
19
27
26
24
23
22
15
21
20
30
29
12
11
13
28
15
16
14
not available unless listed.
37
1
36
2
35
34
33
32
3
31
4
5
6
7
38
8
9
10
Hardware is common and
SD-801 982-A
Figure 7-2. Front Panel Assembly
OM-2221 Page 36
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Front Panel Assembly (Figure 7-1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . 192 866 . . COVER, circuit card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 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 . . . . . . . . . . . . . 186 281 . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
3
4
2
1
1
1
1
1
1
1
1
1
2
2
1
16
4
1
8
2
8
8
8
2
1
5
1
1
1
1
1
2
1
1
2
2
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2221 Page 37
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-3. Rear Panel Assembly (Figure 7-1 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 7-3. 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 38
Notes
OM-2221 Page 39
Notes
OM-2221 Page 40
Effective January 1, 2002
(Equipment with a serial number preface of “LC” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 6/02
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 2002 Miller Electric Mfg. Co.
1/02
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