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OM-225 389B 2005−12 Processes TIG (GTAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source Syncrowave 200 R File: TIG (GTAW) Visit our website at www.MillerWelds.com From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001:2000 Quality Warranty and service information for your System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Mil_Thank 4/05 Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 5 7 2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 9 3-1. Included with Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3-2. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3-3. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3-4. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3-5. Duty Cycle Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3-6. DC Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3-7. AC Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3-8. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3-9. Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3-10. 115 Volts AC Duplex Receptacle And Supplementary Protector CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3-11. Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3-12. Typical TIG Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3-13. Typical Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3-14. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3-15. Connecting Input Power In 208−230 Volt Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4-2. Ammeter, Voltmeter And Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4-3. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4-4. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4-5. Pulse Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4-6. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4-7. Factory Parameter Defaults And Range And Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4-8. Postflow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4-9. Selecting Syncro Start Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 4-10. Pulser Peak And Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4-11. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 4-12. Software Number/Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SECTION 5 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5-2. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 TABLE OF CONTENTS SECTION 7 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING . . . . 8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . . 8-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 32 32 32 33 34 34 35 36 36 37 38 39 48 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Y Only qualified persons should install, operate, maintain, and repair this unit. D D D D D D Y During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. D Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. D When making input connections, attach proper grounding conductor first − double-check connections. D Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill. D D D D D D Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. 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 in inverter-type welding power sources after removal of input power. D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-225 389 Page 1 ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet. D Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection. WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. FLYING METAL can injure eyes. D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. D Wear approved safety glasses with side shields even under your welding helmet. OM-225 389 Page 2 BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator. HOT PARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on gun or torch. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. MAGNETIC FIELDS can affect pacemakers. D Pacemaker wearers keep away. D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. D Wear approved ear protection if noise level is high. CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder − explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place. D Have only qualified persons remove doors, panels, covers, or guards for maintenance as necessary. D Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power. FALLING UNIT can cause injury. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. READ INSTRUCTIONS. D Read Owner’s Manual before using or servicing unit. D Use only genuine Miller/Hobart replacement parts. H.F. RADIATION can cause interference. OVERUSE can cause OVERHEATING D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit. D D STATIC (ESD) can damage PC boards. D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards. D D D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. MOVING PARTS can cause injury. D Keep away from moving parts. D Keep away from pinch points such as drive rolls. D WELDING WIRE can cause injury. D Do not press gun trigger until instructed to do so. D Do not point gun toward any part of the body, other people, or any metal when threading welding wire. D D D D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. 1-4. California Proposition 65 Warnings Y Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) For Gasoline Engines: Y Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Y Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. For Diesel Engines: Y Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. OM-225 389 Page 3 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900, website: www.ansi.org). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000, website: www.nfpa.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000,website: www.nfpa.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices−−phone for Region 5, Chicago, is 312−353−2220,website: www.osha.gov). 1-6. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures: OM-225 389 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 before welding or going near welding operations. If cleared by your doctor, then following the above procedures is recommended. SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette procédure comporte des risques possibles ! Les dangers éventuels sont représentés par les symboles graphiques joints. Y Indique un message de sécurité particulier . Signifie NOTE ; n’est pas relatif à la sécurité. 2-2. Ce groupe de symboles signifie Avertissement ! Attention ! Risques d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES CHAUDES. Consulter les symboles et les instructions afférentes ci-dessous concernant les mesures à prendre pour supprimer les dangers. Dangers relatifs au soudage à l’arc Y Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité. Y Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil. Y Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil. D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il D D D D D D UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort. D Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger. D D D Ne pas toucher aux pièces électriques sous tension. D Porter des gants isolants et des vêtements de protection secs et sans D D D D D D D D D trous. S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol. Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul ! 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 le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes nationales, provinciales et locales. 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. D D D n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu peut entraîner la mort. L’équipement doit être hors tension lorsqu’il n’est pas utilisé. 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. Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée. 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 si l’on doit travailler au-dessus du sol. S’assurer que tous les panneaux et couvercles sont correctement en place. 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. Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereuse pour la santé. D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces vapeurs. D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé. D Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs. D 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. D 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. D 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 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-225 389 Page 5 LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). D Porter des lunettes de sécurité avec écrans latéraux même sous votre casque. D Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc. D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. 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 peuvent provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, une surchauffe ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. D Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections homologuées. D Ne pas souder dans un endroit où des étincelles peuvent tomber sur des substances inflammables. D Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. D Afin d’éliminer tout risque de feu, être vigilant et garder toujours un extincteur à la portée de main. D Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. D Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité). D Brancher le câble de masse 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, d’étincelles et d’incendie. D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. D En cas de non-utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact. D Porter des vêtements de protection exempts d’huile tels que des gants en cuir, une veste résistante, des pantalons sans revers, des bottes et un casque. D Avant de souder, retirer toute substance combustible de ses poches telles qu’un allumeur au butane ou des allumettes. D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B pour travaux de soudage et prévoir un détecteur d’incendie et un extincteur à proximité. DES PARTICULES VOLANTES peuvent blesser les yeux. D Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. OM-225 389 Page 6 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher des parties chaudes à mains nues. D Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche. D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. D Porteurs de stimulateur cardiaque, rester à distance. D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points. LE BRUIT peut endommager l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. D Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé. LES BOUTEILLES peuvent exploser si elles sont endommagées. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. D Ne jamais souder une bouteille pressurisée − risque d’explosion. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état. D Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille. D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur. D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles. D Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité. 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. D S’abstenir de toucher des organes mobiles tels que des ventilateurs. D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. D Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour l’entretien. D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique. LA CHUTE DE L’APPAREIL peut blesser. LIRE LES INSTRUCTIONS. D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire. D Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. L’EMPLOI EXCESSIF peut CHAUFFER L’ÉQUIPEMENT. D Lire le manuel d’utilisation avant d’utiliser ou d’intervenir sur l’appareil. D Utiliser uniquement des pièces de rechange Miller/Hobart. LE RAYONNEMENT HAUTE FRÉQUENCE (HF) risque de provoquer des interférences. SUR- D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal. D Réduire le courant ou le facteur de marche avant de poursuivre le soudage. D Ne pas obstruer les passages d’air du poste. D D D LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. D D D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes PC. LE SOUDAGE À L’ARC risque de provoquer des interférences. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. D D LES FILS DE SOUDAGE peuvent provoquer des blessures. D D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. 2-4. D Le rayonnement haute fréquence (HF) 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 un blindage pour réduire les interférences éventuelles. D D L’énergie électromagnétique peut gêner le fonctionnement d’appareils électroniques comme des ordinateurs et des robots. D 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. Proposition californienne 65 Avertissements Y Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants) Pour les moteurs à essence : Y Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Y Les batteries, les bornes et autres accessoires contiennent du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation. Pour les moteurs diesel : Y Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations congénitales ou autres problèmes de procréation. OM-225 389 Page 7 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site Internet : www.csa-international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 11 West 42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site Internet : www.ansi.org). National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet : www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 178 Rexdale 2-6. OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site Internet : www.osha.gov). Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques. 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. Pour réduire les champs magnétiques sur le poste de travail, appliquer les procédures suivantes : OM-225 389 Page 8 1. Maintenir les câbles ensemble en les tordant ou en les enveloppant. 2. Disposer les câbles d’un côté et à distance de l’opérateur. 3. Ne pas courber pas et ne pas entourer pas les câbles autour de votre corps. 4. Garder le poste de soudage et les câbles le plus loin possible de vous. 5. Connecter la pince sur la pièce aussi près que possible de la soudure. En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur médecin avant de souder ou d’approcher des opérations de soudage. Si le médecin approuve, il est recommandé de suivre les procédures précédentes. SECTION 3 − INSTALLATION 3-1. Included with Your Unit 1 8 2 3 5 7 4 5 6 7 8 9 4 6 9 12 ft (3.7 m) Work Cable With Clamp And Quick-Connect WP1712SFDI 150 Amp TIG Torch with 12 ft (3.7 m) Cable And Quick-Connect Electrode Holder and Quick-Connect Gas Hose Gas Regulator Cable/Torch Hanger Foot Pedal Holder 8 ft (2.4 m) Primary Cord Without Plug RFCS-14 Foot Control with 20 ft (6 m) Cable . Some assembly is required. 3 2 For options and accessories see back of book or contact your distributor. 1 804 464-A 3-2. 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 OR 2 Location And Airflow Line Disconnect Device Locate unit near correct input power supply. For information about sources of high-frequency see Section 7. For carts and caster kits see back of book or contact your distributor. 18 in (460 mm) 18 in (460 mm) 4 Position unit so air can circulate. 4 3 Rating Label Use rating label to determine input power needs. 18 in (460 mm) Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 18 in (460 mm) OM-225 389 Page 9 3-3. Dimensions And Weights B Dimensions C D Height 30-1/8 in (765 mm) Width 21-1/8 in (537 mm) Length 21-1/2 in (546 mm) A 20 in (508 mm) B 3/4 in (19 mm) C 14-3/4 in (375 mm) D 1 in (25 mm) E 4 Holes 1/2 in Dia (13 mm) A E Front 804 239-A Weight 238 lbs (108 kg) 271 lbs (123 kg)* * TIGrunner models 3-4. Specifications Model 208 230 208-230 Welding Rated Output at 40% Duty Cycle Rated Input, 60 HZ, Single-Phase KVA KW Amperage Range Max. OCV DC TIG 150 Amps at 16 Volts 208−230 V−45 A - (2)* 10.2 - (0.50)* 4.3 - (0.3)* 5−200 80 DC Stick 150 Amps at 26 Volts 208-230 V−47 A - (2)* 10.8 - (0.50)* 5.8 - (0.3)* 5−200 80 AC TIG** 150 Amps at 16 Volts 208-230 V−54 A - (2)* 12.3 - (0.50)* 4.5 - (0.3)* 5−200 80 AC Stick 150 Amps at 26 Volts 208-230 V−54 A - (2)* 12.4 - (0.50)* 6 - (0.3)* 5−200 80 Mode * () While idling. ** Input amperage with AC Balance control in the balanced position. Input amperage may be higher with control in an unbalanced position. OM-225 389 Page 10 3-5. Duty Cycle Chart Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit and void warranty. 40% Duty Cycle at 150 A AC/DC 4 Minutes Welding 6 Minutes Resting 226 798-A 3-6. DC Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. 70 60 50 40 DC Stick Min (Max DIG) 30 20 DC Stick Max (Max DIG) 10 0 DC TIG Min 0 50 DC TIG Max 100 150 AMPS 200 250 300 ssb1.1 10/91 − 226 800-A OM-225 389 Page 11 3-7. AC Volt-Ampere Curves 70 Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. AC TIG Min 60 50 AC Stick Max 40 30 AC Stick Min 20 10 AC TIG Max 0 0 50 100 150 200 AMPS ssb1.1 10/91 − 226 799-A 3-8. Weld Output Terminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. 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. Total Cable (Copper) Length In Weld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Weld Output Terminals Y Turn off power before connecting to weld output terminals. Welding Amperes 10 − 60% Duty Cycle 60 − 100% Duty Cycle 100 4 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 Y Do not use worn, damaged, undersized, or poorly spliced cables. Electrode Work 804 234-A 10 − 100% Duty Cycle 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. OM-225 389 Page 12 S-0007-D 3-9. Remote 14 Receptacle Socket* A B K J I H C L N D M G E F A Socket Information A 15 volts DC. B Contact closure to A completes 15 volts DC contactor control circuit. C Command reference; 0 to +10 volts DC output to remote control. D Remote control circuit common. E 0 to +10 volts DC input command signal from remote control. K Chassis common. *The remaining sockets are not used. 3-10. 115 Volts AC Duplex Receptacle And Supplementary Protector CB1 Y Turn Off power before connecting to receptacle or resetting protector. 1 Supplementary Protector CB1 If CB1 opens, high frequency and output to the 115 volts ac duplex receptacle stop. Press button to reset protector. 2 2 115 V 15 Amp AC Receptacle Provides 115 volts, 15 amps of ac power for equipment such as grinders, drills, coolers, etc.. Receptacle is protected from overload by supplementary protector CB1. 1 804 267-B OM-225 389 Page 13 3-11. Shielding Gas Connections Y Turn Off power before connecting to receptacle. 1 4 Tools Needed: 5/8, 1-1/8 in Gas Valve In Fitting Fitting has threads. 5 3 5/8-18 right-hand Located on rear of unit. 2 Gas Valve Out Fitting Gas connection is integrated into the Electrode weld output terminal by means of a flow-through type connector. 3 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 4 Regulator/Flow Gauge Connect regulator/flow gauge to gas cylinder. Connect gas hose to gas in fitting. 5 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). 1 2 804 234-B / 804 235-B OM-225 389 Page 14 3-12. Typical TIG Connections Y Turn off power before making connections. 1 6 2 3 5 7 Remote Foot Control A customer supplied remote fingertip control may also be used. Torch Work Clamp Connect remote control, torch, and work clamp to receptacles as shown. 4 Cylinder Chain or secure cylinder to running gear, wall, or other stationary support. 5 Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. 6 Regulator/Flow Gauge Install so face is vertical. Tools Needed: 7 4 5/8, 1-1/8 in Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour) (9.4 L/min). NOTE: After activating remote control, 0.2 seconds of gas preflow will begin. Preflow Application: Preflow is used to purge the immediate weld area of atmosphere. Preflow also aids in consistent arc starting. Preflow is preset and is not adjustable. Post Flow Application: Postflow is required to cool tungsten and weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance (see Section 4-8). 2 1 3 OM-225 389 Page 15 3-13. Typical Stick Connections Y Turn off power before making connections. 1 2 Electrode Holder Work Clamp Connect electrode holder and work clamp to receptacles as shown. 1 2 3-14. Electrical Service Guide NOTE All values calculated at 40% duty cycle. NOTE Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in table. If actual input voltage is outside of this range, damage to unit may occur. 50/60 Hz Single Phase 208-230 Input Voltage 54 Input Amperes At Rated Output Max Recommended Standard Fuse or circuit breaker Rating In Amperes 1 Time-Delay 2 60 Normal Operating 3 80 Min Input Conductor Size In AWG 4 Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG 4 8 147 (45) 8 Reference: 2005 National Electrical Code (NEC) 1 Choose a circuit breaker with time current curves comparable to a time-delay fuse. 2 “Time-Delay” fuses are UL class “RK5” . 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements. Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. OM-225 389 Page 16 3-15. Connecting Input Power In 208−230 Volt Models Y Installation must meet all National and Local Codes − have only qualified persons make this installation. 1 Y Disconnect and lockout/tagout input power before connecting input =GND/PE Earth Ground conductors from unit. 5 Y Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. 7 4 1 2 3 4 6 L1 L2 1 2 5 6 Black And White Input Conductor (L1 And L2) Green Or Green/Yellow Grounding Conductor Input Power Cord. Disconnect Device (switch shown in the OFF position) Disconnect Device Grounding Terminal Disconnect Device Line Terminals Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. 3 Connect input conductors L1 and L2 to disconnect device line terminals. 7 Over-Current Protection Select type and size of over-current protection using Section 3-14 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. Tools Needed: 804 234-B / Ref. 803 766-B ‘ OM-225 389 Page 17 SECTION 4 − OPERATION 4-1. Controls 6 5 4 0000 7 0000 3 8 2 9 1 222 782-A / 222 790-A 1 Output Selector Switch (Polarity) Y Do not use AC output in damp areas, if movement is confined, or if there is danger of falling. Use AC output ONLY if required for the welding process, and then use a remote control. Y Do not change position of switch while welding or while under load. Use switch to select Direct Current Electrode Negative (DCEN), AC, or Direct Current Electrode Positive (DCEP) output without changing weld output cable connections. 2 Pulse Push Button Control See Section 4-5. 3 Main Amps Push Button (Amperage Control) See Section 4-3. OM-225 389 Page 18 4 Encoder Adjustment Control Use control in conjunction with applicable front panel function switch to set values for that function. 5 Ammeter And Parameter Adjust See Section 4-2. 6 Voltmeter And Parameter Adjust See Section 4-2. 7 Adjust Push Button Control See Section 4-6. 8 Process Push Button Control See Section 4-4. 9 Power Switch Use switch to turn unit On and Off. 4-2. Ammeter, Voltmeter And Parameter Display 1 2 Ammeter Displays actual amperage while welding. Meter also displays preset parameters for any of the following units of measure when they are active: amperage, time, percentage or frequency. 1 2 Voltmeter Displays output or open-circuit voltage while output is on. Meter also displays preset parameters. 4-3. Amperage Control 1 3 2 3 2 200 A 1 Main Amps Push Button (Amperage Control) Encoder Adjustment Control Ammeter See Section 4-7 for Amperage range. Press Main Amps push button, and turn Encoder control to set weld amperage. Weld amperage setting is also peak amperage when Pulser function is active (see Section 4-5). 4-4. Process Control 1 Process Control Press Process button until desired process LED is illuminated: 1 TIG - When selected, an HF (noncontact) arc starting method is activated. Weld output is not available until a remote control is activated. This method can be used with either AC or DC TIG welding. Make connections according to Section 3-12. Y Weld output terminals are energized when power is on, and Output On LED is lit. Stick (SMAW) - When Stick is selected, weld output is on, terminals are energized, and output LED is lit. This method can be used with either AC or DC Stick welding. Make connections according to Section 3-13. OM-225 389 Page 19 4-5. Pulse Control 1 2 PPS 10.0 3 1 2 3 4 Ammeter Voltmeter Encoder Adjustment Control Pulse Control Pulsing is available only while using the TIG process, it cannot be selected if the Stick process (see Section 4-4) is active. Controls can be adjusted while welding. Press Pulse push button to activate pulser function. ON - When illuminated, this LED indicates the pulser is on. 4 Turn Encoder to set pulses per second. See Section 4-7 for Pulse parameters. The selected pulse value is displayed on the ammeter, and [PPS] is displayed on the voltmeter as long as the pulse function is active. Press Pulse control button to turn pulse function off. Press Main Amps or Adjust control button to exit pulse control screen and leave pulser activated. Application: Pulsed TIG welding involves switching the weld output between a high or peak amperage, and a low or background amperage at a controlled rate of pulses per second. Pulsing the weld output from a higher peak amperage, to a lower background amperage, lowers the average welding amperage, which can reduce heat input and improve weld puddle control. Set the number of pulses per second based on the application. Pulsing rates of 1 to 2 pps can improve the timing and amount of filler metal that are added to the weld puddle, improving weld bead consistency. Filler metal should be dipped, or added to the weld puddle when the output pulses to the high, or peak amperage. Fast pulsing rates can improve the bead appearance of welds made without filler, or allow filler to be continuously added to the weld puddle without any dipping action. The pulse rate should be adjusted along with travel speed to obtain desired weld bead appearance. OM-225 389 Page 20 4-6. Balance/DIG Control 2 BAL AC TIG Display DIG DC Stick Display 1 2 3 4 1 7 30% 3 Ammeter Voltmeter Encoder Adjustment Control Adjust Control Select desired process, AC TIG or DC Stick (see Section 4-4). Press Adjust push button to turn Balance/ DIG function and LED on. If AC TIG is selected, turn encoder control to select appropriate balance value (see Section 4-7). The selected value is displayed on the ammeter, and [BAL] is displayed on the voltmeter. Balance changes the AC squarewave output. Set control to 7 and adjust as necessary. Set at a higher value to decrease the arc cleaning (or etching) zone and increase penetration, or set at a lower value to increase arc cleaning action of the workpiece. Application: 4 Joint configuration, set-up, process variables, and oxide thickness may affect setting. Y 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. AC weld output is preferred for aluminum due to the cleaning action it provides. AC balance controls the amount of arc cleaning action which should be adjusted according to how heavy or thick the surface oxides are. Adjust ac balance to the highest setting that provides approximately 0.10 in (2.5 mm) of etching zone along the weld toes, while maintaining a clear, shiny weld puddle. AC balance should be decreased if a distinct etching zone is not visible near the weld toes, or if the weld puddle appears to have dark, pepper-like spots on the surface. If DC Stick is selected, turn encoder control to select appropriate amount of Dig (see Section 4-7). The selected value is displayed on the ammeter, and [DIG] is displayed on the voltmeter. When set at 0, the DIG current will provide no additional short-circuit amperage at low arc voltage. Increasing the DIG percentage increases the short circuit amperage at a low arc voltage to help start and maintain an arc and prevent the electrode from sticking to the workpiece. Application: Increase the DIG percentage to reduce or prevent the electrode from sticking to the workpiece. • For cellulose electrodes (6010, 6011), use a DIG setting of 50 to 80%. • For low hydrogen electrodes (7018), use a DIG setting of 20 to 35%. • For other electrodes, set DIG high enough to prevent electrode sticking. • Setting DIG too high could result in burn thru and digging due to excessive short circuit current. OM-225 389 Page 21 4-7. Factory Parameter Defaults And Range And Resolution Parameter Default Range And Resolution PROCESS TIG HF TIG HF, STICK AC 150 A 5 − 200 Amps DC 150 A 5 − 200 Amps PULSER Off ON / OFF PPS 10 PPS 0.1−15 PPS PEAK t 50% 20 − 80 Percent BKGND A 50% 5 − 95 Percent POSTFLOW Auto 5 - 50 Amps: 5 Seconds A MAIN / PEAK 51 - 200 Amps: Adds 1 Second Per 10 Amps Manual: 1 -25 Seconds DIG 30% 0 − 100 Percent BALANCE 7 1−10 AC Med Soft/Med/Hot DC Med Soft/Med/Hot TIG HF Syncro-Startt Settings OM-225 389 Page 22 4-8. Postflow Control Postflow time is automatically controlled. Auto-postflow provides a minimum of five seconds of postflow for anything less than 50 amps of weld current, and an additional one second of postflow for each additional ten amps of weld current. 3 2 POST AUTO 1 2 3 Power Switch Process Control Encoder Adjust Control To override auto-postflow and set a specific postflow time, press and hold Process push button while turning on power. Hold button for approximately 7 seconds. Voltmeter will display POST, and ammeter will display AUTO. Turn encoder to set desired time in seconds. Postflow settings effects AC and DC TIG, and is not polarity specific. Press torch triger or turn off power to save settings. Application: 1 Auto-postflow time is optimally set based on weld amperage. This amount of auto-postflow time provides adequate shielding with no manual adjustment. The use of auto-postflow at low amperages avoids excessive postflow times and a waste of shielding gas. See Section 4-7 for postflow parameters. OM-225 389 Page 23 4-9. Selecting Syncro Start Characteristics 1 2 3 4 3 DCEN MED Power Switch Main Amps Control Volt And Ammeters Process Selector Switch To change TIG HF Syncro starting characteristics, turn Off power, place Output Selector switch in desired position, DCEN, DCEP or AC. Each position has three start characteristics options. Push and hold Main Amps button and turn on power. Hold button for approximately 7 seconds. 2 Meters will display [AC] [MED] or [DCEN] [MED], or [DCEP] [MED], depending on position of Output Selector switch Turn Encoder to step through the three start characteristics choices. Ammeter displays active choice: soft start, medium start, or hot start. Change polarity (see Section 4-1) to set values for each TIG output. Each setting is polarity specific. Press torch triger or turn off power to save settings. 1 Application: Soft start - use for thin gauge material and small diameter tungstens (.040−1/16 in) Medium start - factory default, used for most welding applications with 1/16, 3/32 and 1/8 in tungstens. 4 OM-225 389 Page 24 Hot start - use for thick materials with a large diameter tungsten (1/8−5/32 in). 4-10. Pulser Peak And Background 1 2 4 Power Switch Pulse Control Push and hold Pulser button and turn on power. Hold button for approximately 7 seconds. 3 50% PK T 2 3 4 Encoder Control Volt And Ammeter Press Pulse button to cycle parameters (see Section 4-7 for parameter ranges). PPS (Pulses Per Second or Pulse Frequency) is used to determine appearance of weld bead (See Section 4-5). PEAK t [PKT] [50%]- The percentage of each pulse cycle that can be spent at the peak amperage level. BKGND A [BKA] [50%] - (Background Amps) - Use Background Amps to set the low pulse of the weld amperage, which cools the weld puddle and affects overall heat input. Background Amps is set as a percentage of peak amperage. 1 Turn encoder to select appropriate value for active pulse parameter. Value selected is shown on the ammeter. 5 Pulsed Output Waveforms Example shows affect changing the Peak Time control has on the pulsed output waveform. NOTE: Peak amperage is set using the Main Amps push button control (see Section 4-3), or with a remote control. Peak amperage is the highest welding amperage allowed to occur in the pulse cycle. Weld penetration varies directly with peak amperage. 5 Application: Percent (%) Peak Time Control Setting Balanced (50%) More Time At Peak Amperage (80%) Pulsed Output Waveforms PPS Bkg Amp Peak Amp Pulsed TIG welding involves switching the weld output between a high or peak amperage, and a low or background amperage at a controlled rate (see Section 4-5). The raised portions of the weld output are controlled in width, height, and frequency, forming pulses of weld output. These pulses and the lower amperage level between them (called the background amperage) alternately heat and cool the molten weld puddle. The combined effect gives the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls can be adjusted while welding. Pulsing can also be used for filler material addition technique training. More Time At Background Amperage (20%) OM-225 389 Page 25 4-11. Timer/Cycle Counter 4 3 0000 0000 2 1234 Hour 59 MINS 5 1234 5678 1 222 782-A / 222 790-A 1 Power Switch 2 Process Control 3 Pulse Control To read timer/cycle counter, press and hold OM-225 389 Page 26 the Process and Pulse buttons, and turn power on. 4 Timer Display The hours are displayed for five seconds, and then the minutes are displayed for five seconds. 5 Cycle Display The cycles are displayed for the next five seconds, and are read as 12,345,678 cycles. 4-12. Software Number/Revision 4 3 0000 161 221 0000 2 5 REV.A 1 222 782-A / 222 790-A 1 2 3 Power Switch Process Control Adjust Control To read software number/revision, press and hold the Process and Adjust buttons, and turn power on. 4 Software Number Display The software number is displayed for five seconds. 5 Revision Display The revision is displayed for the next five seconds. OM-225 389 Page 27 SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace o-ring in Electrode/Gas Output receptacle if cracked. Replace unreadable labels. Repair or replace cracked weld cable. Repair or replace cracked gas hose. 6 Months Blow out or vacuum inside. Or 5-2. Adjusting Spark Gaps 2 3 3 1 Tools Needed: 4 4 804 236-B Y Disconnect and lockout/tagout input power before adjusting spark gaps. Remove right side panel. 1 Tungsten End Of Point Replace point if tungsten end disappears; do not clean or dress tungsten. OM-225 389 Page 28 2 Spark Gap Normal spark gap is 0.008 in (0.203 mm). If adjustment is needed, proceed as follows: 3 Adjustment Screws Loosen screws. Place gauge of proper thickness in spark gap. 4 Pressure Point Apply slight pressure at point until gauge is held firmly in gap. Tighten screws to 12 in/ lbs torque. Adjust other gap. Reinstall right side panel. 5-3. Voltmeter/Ammeter Help Displays . All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. 1 Help 0 Display Indicates a short in the thermal protection circuitry located on the transformer of the unit. If this display is shown, contact a Factory Authorized Service Agent. 2 Help1 Display An SCR overcurrent condition has occurred. Turn power off and back on to correct condition. If problem continues, contact a Factory Authorized Service Agent. 3 Help2 Display Indicates an open in the thermal protection circuitry located on the transformer of the unit. If this display is shown, contact a Fac- 1 3 tory Authorized Service Agent. 4 Help 3 Display Indicates the transformer of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-5). Operation will continue when the unit has cooled. 5 Help 4 Display Indicates an open in the thermal protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent. 6 Help 5 Display Indicates the rectifier assembly of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-5). Op- V A HELP 0 V V A HELP 1 A V A HELP 2 HELP 3 V A V A HELP 4 HELP 5 4 5 6 8 7 9 2 eration will continue when the unit has cooled. 7 Help 6 Display Indicates a short in the thermal protection circuitry located on the rectifier assembly of the unit. If this display is shown, contact a Factory Authorized Service Agent. 8 Help 10 Display Indicates Remote Output control is activated. Release Remote Output control to clear help message. 9 Help 11 Display Indicates Output Selector switch is not in correct position (see Section 4-1). 10 Help 12 Display Indicates a non-allowable set-up on the front panel. V A V A HELP 9 HELP 10 V A V A HELP 11 HELP 12 10 OM-225 389 Page 29 5-4. Troubleshooting NOTE: The remedies listed below are recommendations only. If these remedies do not fix the trouble with your unit, have a Factory Authorized Service Agent check unit. There are no user serviceable parts inside unit. Refer to Section 5-3 for any Help (HLP) message displayed on voltmeter/ammeter. Trouble No weld output; unit completely inoperative. Remedy Place machine power switch in On position (see Section 4-1). Place line disconnect switch in On position (see Section 3-15). Check and replace line fuse(s), if necessary (see Section 3-15). Check for proper input power connections (see Section 3-15). No weld output; unit on. Check, repair, or replace remote control. Have Factory Authorized Service Agent check unit. Unit provides only maximum or minimum weld output. output Make sure Amperage control is in proper position (see Section 4-1). Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-8). Have Factory Authorized Service Agent check unit. Clean and tighten all weld connections. Lay weld cables out straight, do not leave weld cables coiled. Check position of Output Selector control (see Section Figure 4-1). If using remote control, check position of Amperage Adjustment control (see Section 4-1). No control of weld output. Make sure Amperage control is in proper position (see Section 4-1). Lack of high frequency; difficulty in starting GTAW arc. Select proper size tungsten (see Section 8-1). Be sure torch cable is not close to any grounded metal. Check cables and torch for cracked insulation or bad connections. Repair or replace. Check spark gaps (see Section 5-2). Wandering arc − poor control of direction of arc arc. Reduce gas flow rate (see Section 3-12). Select proper size tungsten (see Section 8-1). Properly prepare tungsten (see Section 8-2). Tungsten electrode oxidizing and not remaining bright after conclusion of weld. Shield weld zone from drafts. Increase postflow time (see Section 4-8). Check and tighten all gas fittings. Properly prepare tungsten (see Section 8-2). Fan not operating. Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to protect against overheating. No weld output; fan does not run. Place line disconnect switch in On position (see Section 3-15). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-15). Check for proper input power connections (see Section 3-15). No weld output; fan on. Be sure Output Selector switch is not set between positions (see Section 4-1). Tighten remote control connection to Remote 14 receptacle (see Section 3-9). Check remote control (see remote control Owner’s Manual). Unit overheated. Allow unit to cool (see Section 3-5). Fan not operating; weld output available available. Check for and remove anything blocking fan movement. Have Factory Authorized Service Agent check fan motor. OM-225 389 Page 30 SECTION 6 − ELECTRICAL DIAGRAM 223 956-D Figure 6-1. Circuit Diagram All Models OM-225 389 Page 31 SECTION 7 − HIGH FREQUENCY 7-1. Welding Processes Requiring High Frequency 1 1 High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work TIG high_freq 7/05 − S-0693 7-2. Incorrect Installation Weld Zone 11, 12 50 ft (15 m) 10 14 9 8 7 3 2 13 1 4 Sources of Direct High-Frequency Radiation 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table OM-225 389 Page 32 5 6 Sources of Conduction of High Frequency 7 Input Power Cable 8 Line Disconnect Device 9 Input Supply Wiring Sources of Reradiation of High Frequency 10 Ungrounded Metal Objects 11 Lighting 12 Wiring 13 Water Pipes and Fixtures 14 External Phone and Power Lines S-0694 7-3. Correct Installation 7 Weld Zone 3 50 ft (15 m) 50 ft (15 m) 5 1 6 2 8 4 8 Ground all metal objects and all wiring in welding zone using #12 AWG wire. Nonmetal Building Ground workpiece if required by codes. 9 Metal Building 8 8 11 10 Ref. S-0695 / Ref. S-0695 1 High-Frequency Source (welding power source with built-in HF or separate HF unit) Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable. 2 Center Point of Welding Zone Midpoint between high-frequency source and welding torch. 3 Welding Zone A circle 50 ft (15 m) from center point in all directions. 4 Weld Output Cables Keep cables short and close together. 5 Conduit Joint Bonding and Grounding Electrically join (bond) all conduit sections using copper straps or braided wire. Ground conduit every 50 ft (15 m). 6 Water Pipes and Fixtures Ground water pipes every 50 ft (15 m). 7 External Power or Telephone Lines Metal Building Requirements 9 Metal Building Panel Bonding Methods Bolt or weld building panels together, install copper straps or braided wire across seams, and ground frame. 10 Windows and Doorways Locate high-frequency source at least 50 ft (15 m) away from power and phone lines. Cover all windows and doorways with grounded copper screen of not more than 1/4 in (6.4 mm) mesh. 8 11 Overhead Door Track Grounding Rod Consult the National Electrical Code for specifications. Ground the track. OM-225 389 Page 33 SECTION 8 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING ac/dc_gtaw 2/2000 Y Whenever possible and practical, use DC weld output instead of AC weld output. 8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten ) Amperage Range - Gas Type♦ - Polarity Electrode Diameter DC − Argon − Electrode Negative/Straight Polarity DC − Argon − Electrode Positive/Reverse Polarity AC − Argon AC − Argon − .010” Up to 25 * Up to 20 Up to 15 .020” 15-40 * 15-35 5-20 Balanced Wave 2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens .040” 25-85 * 20-80 20-60 1/16” 50-160 10-20 50-150 60-120 3/32” 135-235 15-30 130-250 100-180 1/8” 250-400 25-40 225-360 160-250 5/32” 400-500 40-55 300-450 200-320 3/16” 500-750 55-80 400-500 290-390 1/4” 750-1000 80-125 600-800 340-525 .010” Up to 15 * Up to 15 Up to 10 .020” 5-20 * 5-20 10-20 .040” 15-80 * 10-60 20-30 1/16” 70-150 10-20 50-100 30-80 3/32” 125-225 15-30 100-160 60-130 1/8” 225-360 25-40 150-210 100-180 5/32” 360-450 40-55 200-275 160-240 3/16” 450-720 55-80 250-350 190-300 1/4” 720-950 80-125 325-450 250-400 .010” * * Up to 20 Up to 15 .020” * * 15-35 5-20 .040” * * 20-80 20-60 1/16” * * 50-150 60-120 3/32” * * 130-250 100-180 1/8” * * 225-360 160-250 5/32” * * 300-450 200-320 3/16” * * 400-550 290-390 1/4” * * 600-800 340-525 Pure Tungsten (Green Band) Zirconium Alloyed Tungsten (Brown Band) ♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour). *Not Recommended. Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers. OM-225 389 Page 34 8-2. Preparing Tungsten Electrode For Welding Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away. A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines 1 1 2 2 Tungsten Electrode Tapered End Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality. 2-1/2 Times Electrode Diameter 1 1 2 Stable Arc Flat 2 Diameter of this flat determines amperage capacity. 3 3 Grinding Wheel Grinding wheel should be dedicated to grinding tungsten only. 4 4 Straight Ground 1 2 3 Arc Wander Point Grinding Wheel Ideal Tungsten Preparation − Stable Arc 1 2 3 Grinding wheel should be dedicated to grinding tungsten only. 4 Radial Ground 1 2 Tungsten Electrode Balled End 4 Wrong Tungsten Preparation − Wandering Arc B. Preparing Tungsten For Conventional AC Welding Y Understand and follow safety symbols at start of Section 9-1 before preparing tungsten. 1 1 − 1-1/2 Times Electrode Diameter Ball end of tungsten by applying AC amperage recommended for a given electrode diameter (see Section 8-1). Let ball on end of the tungsten take its own shape. 2 OM-225 389 Page 35 SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) 9-1. Positioning The Torch Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. . For additional information, see 3 your distributor for a handbook on the Gas Tungsten Arc Welding (GTAW) process. 2 1 Workpiece Make sure workpiece is clean before welding. 4 2 Work Clamp Place as close to the weld as possible. 90° 3 4 5 6 1 Torch Filler Rod (If Applicable) Gas Cup Tungsten Electrode Select and prepare tungsten according to Sections 8-1 and 8-2. Guidelines: 10−15° 4 5 6 10−25° 5 The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage. (For example, if tungsten is 1/16 in diameter, gas cup should be a minimum of 3/16 in diameter. Tungsten extension is the distance the tungsten extends out gas cup of torch. 6 The tungsten extension should be no greater than the inside diameter of the gas cup. Arc length is the distance from the tungsten to the workpiece. 1/16 in 3/16 in Bottom View Of Gas Cup Ref. ST-161 892 OM-225 389 Page 36 9-2. Torch Movement During Welding Tungsten Without Filler Rod 75° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod 75° Welding direction Form pool Tilt torch Remove rod 15° Add filler metal Move torch to front of pool. Repeat process. ST-162 002-B OM-225 389 Page 37 9-3. Positioning Torch Tungsten For Various Weld Joints 90° Butt Weld And Stringer Bead 70° 20° 20° “T” Joint 75° 10° 15° 20-40° Lap Joint 75° 15° 30° 90° Corner Joint 75° 15° ST-162 003 / S-0792 OM-225 389 Page 38 SECTION 10 − STICK WELDING (SMAW) GUIDELINES 10-1. Stick Welding Procedure Y Weld current starts when electrode touches workpiece. Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. 1 5 2 3 4 2 Work Clamp Electrode A small diameter electrode requires less current than a large one. Follow electrode manufacturer’s instructions when setting weld amperage (see Section 10-2). 3 6 1 Workpiece Make sure workpiece is clean before welding. 7 4 5 6 Insulated Electrode Holder Electrode Holder Position Arc Length Arc length is the distance from the electrode to the workpiece. A short arc with correct amperage will give a sharp, crackling sound. 7 Slag Use a chipping hammer and wire brush to remove slag. Remove slag and check weld bead before making another weld pass. Tools Needed: stick 12/96 − ST-151 593 OM-225 389 Page 39 7014 7018 7024 Ni-Cl 308L ALL DEEP EP ALL DEEP 6013 EP,EN ALL LOW GENERAL 7014 EP,EN ALL MED 7018 EP ALL LOW SMOOTH, EASY, FAST LOW HYDROGEN, STRONG 7024 EP,EN NI-CL EP FLAT HORIZ FILLET ALL 308L EP ALL USAGE PENETRATION EP 6011 AC 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 DC* 450 400 350 300 AMPERAGE RANGE 250 200 150 POSITION 6013 6010 ELECTRODE 6010 & 6011 100 50 DIAMETER ELECTRODE 10-2. Electrode and Amperage Selection Chart MIN. PREP, ROUGH HIGH SPATTER LOW SMOOTH, EASY, FASTER LOW CAST IRON LOW STAINLESS *EP = ELECTRODE POSITIVE (REVERSE POLARITY) EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY) Ref. S-087 985-A 10-3. Striking an Arc − Scratch Start Technique 1 1 2 3 Electrode Workpiece Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it. 2 3 S-0049 10-4. Striking an Arc − Tapping Technique 1 1 2 3 2 Electrode Workpiece Arc Bring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it. 3 S-0050 OM-225 389 Page 40 10-5. Positioning Electrode Holder 10°-30° 90° 90° End View of Work Angle Side View of Electrode Angle GROOVE WELDS 10°-30° 45° 45° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 10-6. Poor Weld Bead Characteristics 1 2 3 4 5 Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration 1 2 4 3 5 S-0053-A 10-7. Good Weld Bead Characteristics 1 2 3 Fine Spatter Uniform Bead Moderate Crater During Welding Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded. 4 5 1 2 3 4 No Overlap Good Penetration into Base Metal 5 S-0052-B OM-225 389 Page 41 10-8. Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Angle Too Small Correct Angle 10° - 30° Angle Too Large Drag ELECTRODE ANGLE Spatter Normal Too Short Too Long ARC LENGTH Normal Slow Fast TRAVEL SPEED S-0061 10-9. Electrode Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads work better. 1 2 1 2 3 Stringer Bead − Steady Movement Along Seam Weave Bead − Side to Side Movement Along Seam Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of electrode. 3 S-0054-A OM-225 389 Page 42 10-10. Butt Joints 1 1 2 Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position before final weld. 2 Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. 3 1/16 in (1.6 mm) Single V-Groove Weld Good for materials 3/16 − 3/4 in (5-19 mm) thick. Cut bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels. 30° 4 3 Create 30 degree angle of bevel on materials in V-groove welding. 4 Double V-Groove Weld Good for materials thicker than 3/16 in (5 mm). S-0662 10-11. Lap Joint 30° Or Less 30° Or Less 1 1 Single-Layer Fillet Weld Electrode Single-Layer Fillet Weld Move electrode in circular motion. 3 Multi-Layer Fillet Weld Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass. Weld both sides of joint for maximum strength. 3 2 1 2 Multi-Layer Fillet Weld S-0063 / S-0064 10-12. Tee Joint 1 2 Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. 1 2 45° Or Less Electrode Fillet Weld For maximum strength weld both sides of upright section. 2 3 Multi-Layer Deposits Weld a second layer when a heavier fillet is needed. Use any of the weaving patterns shown in Section 10-9. Remove slag before making another weld pass. 1 3 S-0060 / S-0058-A / S-0061 OM-225 389 Page 43 10-13. Weld Test 1 2 3 3 Strike weld joint in direction shown. A good weld bends over but does not break. 3 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) Vise Weld Joint Hammer 2 To 3 in (51-76 mm) 2 2 1 1 S-0057-B 10-14. Troubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding. 10-15. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high. Reduce arc length or voltage. OM-225 389 Page 44 10-16. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding. Adjust work angle or widen groove to access bottom during welding. Momentarily hold arc on groove side walls when using weaving technique. Keep arc on leading edge of weld puddle. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding. 10-17. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Reduce travel speed. 10-18. Troubleshooting − Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Possible Causes Excessive heat input. Good Penetration Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. OM-225 389 Page 45 10-19. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Excessive heat input. Corrective Actions Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 10-20. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. Possible Causes Unsteady hand. Corrective Actions Use two hands. Practice technique. 10-21. Troubleshooting − Distortion Distortion − contraction of weld metal during welding that forces base metal to move. Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input. Corrective Actions Use restraint (clamp) to hold base metal in position. Make tack welds along joint before starting welding operation. Select lower amperage for electrode. Increase travel speed. Weld in small segments and allow cooling between welds. OM-225 389 Page 46 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. OM-225 389 Page 47 SECTION 11 − PARTS LIST . Hardware is common and not available unless listed. 23 57 30 22 21 31 32 28 33 29 18 17 20 19 16 26 24 34 25 14 15 7 10 9 8 35 36 13 12 11 38 6 2 40 39 5 25 37 41 42 43 1 57 27 4 51 3 52 53 54 50 47 49 48 55 46 45 44 57 56 804 237-C Figure 11-1. Main Assembly OM-225 389 Page 48 Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-1. Main Assembly . . . 1 . . . . . . . . . . 223 302 . . . 2 . . . . . . . . . . 222 779 . . . 3 . . . . . . . . . . 169 136 . . . 4 . . . . . . . . . . 175 952 . . . 5 . . . . . . . . . . 195 778 . . . 6 . . . . . . . . . . 222 782 . . . 7 . . . . . . . . . . 222 776 . . . 8 . . . . . . . . . . 183 332 . . . 9 . . . . . . . . . . 224 498 . . . 10 . . . . . . . . . . 190 512 . . . 11 . . . . S5 . . 222 793 . . . 12 . . . . S1 . . 128755 . . . 13 . . C5,C6 . 223 952 . . . 14 . . . PC1 . . 221 156 . . . 15 . . T1/Z1 . 223 299 . . . 16 . . . . . . . . . . 224 442 . . . 17 . . . . . . . . . . 199 479 . . . 18 . . . . . . . . . . 222 774 . . . 19 . . . . . . . . . . 201 019 . . . 20 . . . . . . . . . . 203 990 . . . 21 . . . . . . . . . . 223 303 . . . 22 . . . . . . . . . +225 673 . . . 23 . . . . . . . . . . 213 073 . . . 24 . . . . . . . . . . 224 441 . . . 25 . . R1,R4 . 220 808 . . . 26 . . . . . . . . . . 213 072 . . . 27 . . . . . . . . . . 223 300 . . . 28 . . . . . . . . . . 222 778 . . . 29 . . . GS . . 216 607 . . . 30 . . . . . . . . . +222 777 . . . 31 . . . . . . . . . . 604 102 . . . 32 . . . . . . . . . . 190 442 . . . 33 . . . . . . . . . . 137 761 . . . 34 . . . . . . . . . . 185 759 . . . 35 . . . SR2 . . 035 704 . . . 36 . . . CR1 . . 173 069 . . . 37 . . . . R2 . . 189 132 . . . 38 . . . . C1 . . 191 944 . . . 39 . . . HD1 . . 191 941 . . . 40 . . . . . . . . . . 224 496 . . . 41 . . . . . . . . . +222 781 . . . 42 . . . . . . . . . . 224 460 . . . 43 . . . C18 . . 195 552 . . . 44 . . . . C3 . . 215 779 . . . 45 . . . . T3 . . 219 927 . . . 46 . . . . G1 . . 221 738 . . . . . . . . . . . . . . . . 221735 . . . . . . . . . . . . . . . . 221734 . . . . . . . . . . . . . . . . 221736 . . . . . . . . . . . . . . . . 221737 . . . 47 . . . . R8 . . 211 261 . . . 48 . . . . . . . . . . 222 773 . . . 49 . . . C14 . . 206 878 . . . 50 . . . . T4 . . 222 793 . . . 51 . . . . . . . . . . 207 560 . . . 52 . . . . . . . . . . 222 790 . . . 53 . . . . . . . . . . 218 170 . . . 54 . . . . . . . . . . 089 120 . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT, BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIN, HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLASTIC, HANDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACTUATOR PUSH BUTTON ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, SYNCROWAVE 200 UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, POINTER .570 DIA X .125 ID W/SPRING CLIP . . . . . . . . . . . . . . . . . . . . BUSHING, FLG 375−32X423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND−OFF,NO 6−32 X .640 LG .250 HEX AL FEM . . . . . . . . . . . . . . . . . . . . . . SWITCH ASSY, POLARITY W/LEADS & HARDWARE . . . . . . . . . . . . . . . . . . . SWITCH, TGL DPST 40A 600VAC SCR TERM WIDE TGL . . . . . . . . . . . . . . . . CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD ASSY, CONTROL & INTERFACE W/PROGRAM . . . . . . . . . . XFMR/STABILIZER ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, MILLER 9.562 X 4.000 HORIZONTAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, WARNING ELECTRIC SHOCK EXCESS WEIGHT . . . . . . . . . . . . . . . . LABEL, WARNING GENERAL PRECAUTIONARY STATIC . . . . . . . . . . . . . . . . HANGER,CABLE/TORCH (PART OF ACCESSORY KIT) . . . . . . . . . . . . . . . . . . COVER, TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAL, LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLENUM, MID PLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW FXD 100 W 50 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . FAN, MUFFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, FOOT PEDAL (PART OF ACCESSORY KIT) . . . . . . . . . . . . . . . . . . . BAFFLE, FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, 24VDC 2WAY CUSTOM PORT 1/8 ORF W/FRICT . . . . . . . . . . . . . . . . . PANEL, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONN, CLAMP CABLE 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CORD SET ,250V 8GA 3/C 10’-4” ST JKT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, 750 NPT 1.31HEX .27H NYL BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, WARNING ELECTRIC SHOCK & INPUT POWER . . . . . . . . . . . . . . . . . RECTIFIER, INTEG BRIDGE 40. AMP 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY,ENCL 12VDC SPDT 30A/20A 5PIN FLANGE MTG . . . . . . . . . . . . . . . . RESISTOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, POLYP MET FILM 10. UF 250 VAC 10% . . . . . . . . . . . . . . . . . . . . TRANSDUCER, CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECTIFIER ASSY, (FIGURE 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, WARNING ELECTRICAL SHOCK SPARK GAP(ENG/FR) . . . . . . . . . . CAPACITOR, POLYP MET FILM 20. UF 250 VAC 10% . . . . . . . . . . . . . . . . . . . . CAPACITOR, MICA .002 UF 10000 V PANEL MTG W/LEA . . . . . . . . . . . . . . . . . XFMR, HIGH VOLTAGE 115V PRI 3600V SEC 34 MA W/TERM . . . . . . . . . . . . SPARK GAP ASSY, HF (INCLUDES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLDER, POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POINTS, SPARK GAP (DUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POINTS, SPARK GAP (SINGLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW FXD 100 W 200 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . . . . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COIL, COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, STAND−OFF WITH STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, SYNCROWAVE 200 LOWER ......................... . . HOSE, NPRN BRD NO 1 X .250 ID X 25.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, HOSE .375 − .450 CLP DIA SLFTTNG GREEN . . . . . . . . . . . . . . . . . 2 1 1 1 4 1 1 1 1 5 1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 2 1 1 1 1 2 1 1 2 OM-225 389 Page 49 Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-1. Main Assembly (continued) . . . 55 . . . C13 . . 209 587 . . CAPACITOR ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 . . . . . . . . . . 223 981 . . PANEL, LOWER DINSE CONN ASSY (FIGURE11-2) . . . . . . . . . . . . . . . . . . . . . . 57 . . . . . . . . . . 224 452 . . FACTORY OPTIONAL RUNNING GEAR (FIGURE 11-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 162 . . HOUSING PLUG+PINS, (SERVICE KIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 452 . . KIT, ACCESSORY (INCLUDES) (ALSO INCLUDES ITEMS 21 AND 27) . . . . . . . . . . . . . . . . . . . . . . . . . . . (SEE FIGURE 3-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 282 . . . . . . . . RFCS-14, FOOT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 860 . . . . . . . . WORK CABLE, W/CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 121 . . . . . . . . REGULATOR/FLOWMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 840 . . . . . . . . HOLDER, ELECTRODE W/CABLE & DINSE CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . 198 317 . . . . . . . . HOSE, GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP1712SFDI50 . . . . . . TORCH PKG, 150A, 12FT, AIR, W/ 50MM FLOW CONNECTOR . . . 1 1 1 0 1 1 1 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-225 389 Page 50 . Hardware is common and not available unless listed. 3 4 5 6 3 5 4 2 7 8 1 9 10 7 8 12 9 11 803 775-A Figure 11-2. Panel, Lower Dinse Connector Assembly Item No. Dia. Mkgs. Part No. Description 223 981 ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... 213 109 218 174 185 717 185 714 185 713 224 529 185 718 185 712 186 228 202 811 202 553 218 784 .. .. .. .. .. .. .. .. .. .. .. .. Quantity 11-2. Panel, Lower Dinse Connector Assy (Figure 11-1 Item 56) PANEL, LOWER DINSE CONN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, W/LEADS & CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . NUT, M20−1.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, TOOTH 22MMID X 31.5MMOD 1.310−1MMT INTERN . . . . . . . . . INSULATOR, BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONN, CIRC MS/CPC 14SKT SIZE 20 RCPT W/FILTERING . . . . . . . . . . . . . O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE,TWIST LOCK ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE, TWIST LOCK BRASS POWER (FEMALE) . . . . . . . . . . . . . . . LABEL, COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2 2 2 1 2 2 2 1 1 1 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-225 389 Page 51 1 . Hardware is common and not available unless listed. 3 2 4 804 399-A Figure 11-3. Rectifier Assembly Item No. Dia. Mkgs. Part No. Description 224 496 ... ... ... ... 1 2 3 4 .......... .......... .......... .......... 206 984 206 327 224 488 208 384 .. .. .. .. Quantity Figure 11-3. Rectifier Assembly (Figure 11-1 Item 40) HEAT SINK,RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMISTOR,NTC 30K OHM @ 25 DEG C 27IN LEAD . . . . . . . . . . . . . . . . . BUS BAR,RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THYRISTOR,SCR MODULE 136A 400V DUAL . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2 2 NOTE: 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-225 389 Page 52 2 . Hardware is common and 3 not available unless listed. 1 4 5 6 7 8 9 6 Optional 10 7 11 8 12 804 414-B Figure 11-4. Factory Optional Running Gear Item No. Dia. Mkgs. Part No. Description Quantity Figure 11-4. Factory Optional Running Gear (Figure 11-1 Item 57) ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 . . . . . . . . . +222 775 . . . . . . . . . . 168 663 . . . . . . . . . . 210 224 . . . . . . . . . . 200 285 . . . . . . . . . . 223 296 . . . . . . . . . . 209 869 . . . . . . . . . . 602 250 . . . . . . . . . . 121 614 . . . . . . . . . . 602 154 . . . . . . . . . . 193 632 . . . . . . . . . . 223 293 . . . . . . . . . . 008 999 .. .. .. .. .. .. .. .. .. .. .. .. COVER, TOP W/BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOOK, SPRING .2502.375 LG .312 SNAP OPENING . . . . . . . . . . . . . . . . . . CHAIN, STRAIGHT LINK 1/0 X 27. BRIGHT ZINC PLD . . . . . . . . . . . . . . . . . LABEL, WARNING CYLINDER MAY EXPLODE IF DAMAGED . . . . . . . . . . CYLINDER, RACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL, POLY−OLEFIN 10 IN DIAX 2.000WIDEX.750 ................ WASHER, FLAT .812IDX1.469ODX.134T STL PLD ANSI.750 . . . . . . . . . . . . RING, RTNG EXT .750 SHAFT X .085 THK E STYLE PLD ............ SCREW,250−20X .50 HEXWHD.50D STL PLD SLFFMG TAP−RW ..... NUT, 375−16 .56HEX .34H STL PLD SER FLANGE . . . . . . . . . . . . . . . . . . BRACKET, CASTER MTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CASTER, SWVL 4.00 IN POLYOLEFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 1 1 1 2 2 2 12 2 1 2 +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-225 389 Page 53 Notes Effective January 1, 2005 (Equipment with a serial number preface of “LF” 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. * Induction Heating Coils and Blankets * APT & SAF Model Plasma Cutting Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate Spoolguns * Canvas Covers 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’s True Blue® Limited Warranty shall not apply to: 1. 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. 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. 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 Sources (Unless Otherwise Stated) * Water Coolant Systems (Integrated) * * * Intellitig Maxstar 150 Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor Unless Specified * * * * * * * * * * * * * * * * * * * DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate Spoolguns) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources and Coolers Water Coolant Systems (Non-Integrated) Flowgauge and Flowmeter Regulators (No Labor) HF Units Grids Maxstar 85, 140 Spot Welders Load Banks Arc Stud Power Sources & Arc Stud Guns 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 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 1/05 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 Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories 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 To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller Contact the Delivering Carrier to: www.MillerWelds.com 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 © 2005 Miller Electric Mfg. Co. 1/05
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