Miller SYNCROWAVE 200 Owner’s Manual

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