Miller SYNCROWAVE 210 Owner’s Manual

OM-261726G
2017-03
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
)
Syncrowave 210
File: TIG (GTAW)
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Included with Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Remote 14 Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Shielding Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Weld Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Removing Power Pin Style Connector To Adapt Spoolmate 100/150 Models For Use With
The Syncrowave 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Installing Dinse Style Connector To Adapt Spoolmate 100/150 Models For Use With
The Syncrowave 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Adapter Cord Connections To Adapt Spoolmate 100/150 Models For Use With The
Syncrowave 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Connecting 115 Volts Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Multi−Voltage Plug (MVP) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Syncrowave 210 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Accessing Control Panel Menu: AC TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Accessing DC TIG Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Accessing DC Stick Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Accessing Spool Gun Control Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Accessing User Setup Menu: AC And DC TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Accessing User DC Stick Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Accessing User Spool Gun Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ADVANCED MENU FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Accessing Tech Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Meter Troubleshooting Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . .
11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
COMPLETE PARTS LIST − Available at www.MillerWelds.com
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
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Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-261726 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
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D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the 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.
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.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
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.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D
D Sparks can cause fires — keep flammables away.
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.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-261726 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-261726 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
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.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
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 Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D 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.
D 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.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D 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 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 !
D 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).
D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
D 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.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
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.
OM-261726 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
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 FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
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. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
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.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
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 pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
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 un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surOM-261726 Page 6
chauffement 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 homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de 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 Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
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 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
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 un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans 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.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé 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.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
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.
Les bouteilles de gaz comprimé 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 comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
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.
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.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
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.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
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.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
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 de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer 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.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
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.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
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 Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
OM-261726 Page 7
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D 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 Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D 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).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D 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.
2-4. Proposition californienne 65 Avertissements
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)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-261726 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
. A complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not move or operate unit where it could tip.
Safe 113 2013−04
3-2. Miscellaneous Symbols And Definitions
A
V
Amperes
U1
Volts
Remote
Protective Earth
(Ground)
On
Off
Alternating
Current
I2
Rated Welding
Current
X
Duty Cycle
U2
U0
IP
I1max
I1eff
Hz
Primary Voltage
Output
Line Connection
Suitable For
Areas Of
Increased Shock
Hazard
S
Conventional
Load Voltage
Alternating
Current (AC) And
Direct Current
(DC)
Rated No Load
Voltage (OCV)
Direct Current
(DC)
Degree Of
Protection
Gas Tungsten Arc
Welding (GTAW)
Rated Maximum
Supply Current
Maximum
Effective Supply
Current
Hertz
Percent
Shielded Metal
Arc Welding
(SMAW)
Up
Rated Peak
Voltage
Inverter Power
Source With
AC/DC Output
Notes
OM-261726 Page 9
. A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Included with Your Unit
1
5
2
3
4
5
6
7
8
9
4
6
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
Power Cable Adapter
Cable/Torch Hanger
Foot Pedal Holder
RFCS-14 Foot Control with
20 ft (6 m) Cable
. Some assembly is required.
3
7
9
For options and accessories see
back of book or contact your distributor.
8
2
1
805522-A
4-2. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the rear of the machine. Use the rating labels to determine input power
requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
Notes
OM-261726 Page 10
. A complete Parts List is available at www.MillerWelds.com
4-3. Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-8, 5-10 and/or 5-11 for information
on connecting input power.
. This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Input
Power
Process
Welding
Amperage
Range
Rated Output
Amps Input At
Rated Output
KVA
KW
75 A at 13 V, 100% Duty Cycle
13.2 (.58)*
1.54 (.07)*
1.46 (.02)*
DC TIG
5 − 125
95 A at 13.8 V, 60% Duty Cycle
17.4 (.58)*
2.05 (.07)*
1.94 (.02)*
125 A at 15 V, 35% Duty Cycle
25.2 (.58)*
3.04 (.07)*
2.79 (.02)*
115 VAC
AC TIG
Stick
5 - 114
20 − 90
5 − 210
DC TIG
230 VAC
AC TIG
Stick
5 - 184
20 -150
75 A at 13 V, 100% Duty Cycle
10.4 (.58)*
1.20 (.07)*
1.12 (.02)*
90 A at 13.6 V, 60% Duty Cycle
12.4 (.58)*
1.43 (.07)*
1.33 (.02)*
114 A at 14.6 V, 35% Duty Cycle
18.3 (.58)*
2.11 (.07)*
1.98 (.02)*
55 A at 22.2 V, 100% Duty Cycle
15.6 (.58)*
1.84 (.07)*
1.74 (.02)*
70 A at 22.8 V, 60% Duty Cycle
20.5 (.58)*
2.47 (.07)*
2.30 (.02)*
90 A at 23.6 V, 35% Duty Cycle
25.9 (.58)*
3.14 (.07)*
2.87 (.02)*
95 A at 13.8 V, 100% Duty Cycle
8.4 (.35)*
1.96 (.08)*
1.84 (.02)*
125 A at 15 V, 60% Duty Cycle
11.9 (.35)*
2.72 (.08)*
2.61 (.02)*
150 A at 16 V, 40% Duty Cycle
14.7 (.35)*
3.43 (.08)*
3.31 (.02)*
210 A at 18.4 V, 20% Duty Cycle
23.6 (.35)*
5.56 (.08)*
5.35 (.02)*
90 A at 13.6 V, 100% Duty Cycle
6.6 (.35)*
1.53 (.08)*
1.44 (.02)*
114 A at 14.6 V, 60% Duty Cycle
8.62 (.35)*
1.99 (.08)*
1.91 (.02)*
138 A at 15.5 V, 40% Duty Cycle
12.1 (.35)*
2.80 (.08)*
2.69 (.02)*
184 A at 17.4 V, 20% Duty Cycle
16.6 (.35)*
3.84 (.08)*
3.77 (.02)*
60 A at 22.4 V, 100% Duty Cycle
7.9 (.35)*
1.84 (.08)*
1.72 (.02)*
90 A at 23.6 V, 60% Duty Cycle
11.9 (.35)*
2.79 (.08)*
2.68 (.02)*
150 A at 26 V, 20% Duty Cycle
21.8 (.35)*
5.12 (.08)*
4.94 (.02)*
Max. OCV
47 VDC
47 VDC
( )* While idling.
4-4. Dimensions And Weights
Dimensions
B
A
31-1/2 in. (800 mm)
B
18-1/2 in. (470)
C
43 in. (1092)
A
C
805519-A
Weight
134 lb (60.8 kg)
OM-261726 Page 11
. A complete Parts List is available at www.MillerWelds.com
WELD AMPERES
4-5. Duty Cycle Chart
220
210
200
190
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
Duty cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
TIG - 230 VAC
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Stick - 230 VAC
TIG - 115 VAC
Stick - 115 VAC
100
50
10
% DUTY CYCLE
40% Duty Cycle at 150 A AC/DC
4 Minutes Welding
6 Minutes Resting
260380-A
4-6. Environmental Specifications
A. IP Rating
IP Rating
IP23S
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23S 2014−06
B. Temperature Specifications
Operating Temperature Range
Storage/Transportation Temperature Range
14 to 104°F (−10 to 40°C)
−22 to 131°F (−30 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
Notes
OM-261726 Page 12
Temp_2016- 07
. A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Movement
!
Do not move or operate unit
where it could tip.
Location And Airflow
1
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
2
Line Disconnect Device
Running Gear
Locate unit near correct input power supply.
For information about sources of
high-frequency see Section 10.
18 in. (460 mm)
18 in. (460
mm)
2
18 in. (460 mm)
18 in. (460 mm)
loc_cart mount 2015-08
OM-261726 Page 13
. A complete Parts List is available at www.MillerWelds.com
5-2. Remote 14 Receptacle
Socket*
A
B
K
J
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.
G
Spool gun motor common.
I
Spool gun motor, +3.5 to 15 VDC.
J
Spool gun detect, 0 VDC when spool gun is connected, +3.3
VDC with no spool gun attached.
K
Chassis common.
I
H
C L N
M
D
G
E F
*The remaining sockets are not used.
Notes
OM-261726 Page 14
A
. A complete Parts List is available at www.MillerWelds.com
5-3. Shielding Gas Connections
. Use
argon shielding gas for
best performance.
2
1
Tools Needed:
5/8, 1-1/8 in.
1
3
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
2
Regulator/Flow Gauge
Connect regulator/flow gauge to
gas cylinder. Do not over tighten.
Connect gas hose to gas in fitting.
3
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour).
Ref. 805519-A
5-4. Weld Output Connections
1
Electrode Output Terminal
For Stick (SMAW) connect electrode holder to this terminal.
For TIG (GTAW), connect torch to
this terminal.
For MIG (GMAW) connect spool
gun to this terminal.
2
3
3
1
OR
Work Terminal
Connect work
terminal.
clamp
to
this
Process Selector
Use control to select weld process
(see Section 6-1).
OR
2
805521-A
OM-261726 Page 15
. A complete Parts List is available at www.MillerWelds.com
5-5. Removing Power Pin Style Connector To Adapt Spoolmate 100/150 Models For Use
With The Syncrowave 210
!
Turn Off welding power source and
disconnect spool gun.
Photo 1 −Power Pin Style Connector
Power pin style connector that comes standard with the spool gun must be changed to
a Dinse style connector for use with the Syncrowave 210.
3
2
4
Strain relief
Turn strain relief cap 1/4 turn counter clockwise, and slide strain relief down cable.
5
6
Phillips Screw
Handle
Remove screw, and handle.
7
Power Pin Connector
Use 13 and 17 mm wrenches to remove power pin style connector.
1
4
5-6. Installing Dinse Style Connector To Adapt Spoolmate 100/150 Models For Use With
The Syncrowave 210
1
!
Turn Off welding power source and
disconnect spool gun.
1
Dinse Style Connector
Screw on Dinse style connector and tighten
with 13 and 17 mm wrenches.
Slide handle back into position, and secure
with Phillips screw removed earlier.
Slide strain relief into position, and tighten
strain relief cap.
OM-261726 Page 16
. A complete Parts List is available at www.MillerWelds.com
5-7. Adapter Cord Connections To Adapt Spoolmate 100/150 Models For Use With The
Syncrowave 210
!
Turn Off welding power
source before connecting
adapter cable.
1
2
4 To 14-Pin Adapter
14-Pin Receptacle
Insert spool gun control cable 4-pin
plug into matching receptacle on
4-pin adapter cord and tighten collar.
Connect 14−pin plug end of adapter
cord to matching 14-pin receptacle
on welding power source and tighten
collar.
1
2
805521-A
5-8. Electrical Service Guide
Elec Serv 2017-01
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
60 Hz Single-Phase
230 Volts AC
Input Voltage (V)
Rated Maximum Supply Current I1max (A)
24
Maximum Effective Supply Current I1eff (A)
11
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2
30
Normal Operating Fuses 3
35
Min Input Conductor Size In AWG
(mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG (mm2) 4
14
115 Volts AC
A 15 or 20 ampere individual branch
circuit protected by time-delay fuses or
circuit breaker is required.
See Section 5-10
48(15)
14
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
OM-261726 Page 17
. A complete Parts List is available at www.MillerWelds.com
5-9.
Selecting Extension Cord (Use Shortest Cord Possible)
Conductor Size − AWG (mm2)*
Single Phase AC
Input Voltage
4 (21.2)
6 (13.3)
8 (8.4)
10 (5.3)
12 (3.3)
Maximum Allowable Cord Length in ft (m)
115
160 (49)
107 (33)
71 (22)
47 (14)
29 (9)
230
471 (144)
321 (98)
215 (66)
146 (45)
90 (27)
*Conductor size is based on maximum 3% voltage drop
5-10. Connecting 115 Volts Input Power
!
Installation must meet all National and Local Codes
− have only qualified persons make this installation.
!
Special installation may be required where gasoline or
volatile liquids are present − see NEC Article 511 or CEC
Section 20.
. The Auto-Line circuitry in this unit automatically links the
power source to the primary voltage being applied, either
115 or 230 VAC.
For 115 volts AC input power, a 15 or 20 ampere individual
branch circuit protected by time-delay fuses or circuit breaker is
required.
1
Multi-Voltage Plug And Power Cord Connector (NEMA
Type 5−15P Plug Shown)
For multi−voltage plug connections, see Section 5-12.
2
Receptacle − NEMA Type 5−15R (Customer Supplied)
1
2
Input6 2011−03 Ref. 805474-A Ref. 805519-A
OM-261726 Page 18
. A complete Parts List is available at www.MillerWelds.com
Notes
OM-261726 Page 19
. A complete Parts List is available at www.MillerWelds.com
5-11. Connecting 1-Phase Input Power
1
3
=GND/PE Earth Ground
7
2
4
L1
L2
5
6
1
8
9
L1
L2
230 VAC, 1
Tools Needed:
input4 2012−05 − Ref. 803766-C / Ref. 805519-A / Ref. 805540-A
OM-261726 Page 20
. A complete Parts List is available at www.MillerWelds.com
5-11. Connecting 1-Phase Input Power (Continued)
!
!
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
. The Auto-Line circuitry in this unit auto-
matically links the power source to the
primary voltage being applied, either 115
or 230 VAC.
See rating label on unit and check input voltage available at site.
1
2
3
4
5
6
Input Power Cord
Disconnect Device (switch shown in the
OFF position)
Disconnect Device Grounding Terminal
Disconnect Device Line Terminals
Black And White Input Conductor (L1
And L2)
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
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 5-8 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures to put unit in service.
8
Multi-Voltage Plug And Power Cord
Connector (NEMA 6-50P Plug Shown)
For multi−voltage plug connections, see Section 5-12.
9
Receptacle (NEMA 6-50R)
(Customer Supplied)
Connect plug to receptacle.
input4 2012−05 − 803766-C
Notes
OM-261726 Page 21
. A complete Parts List is available at www.MillerWelds.com
5-12. Multi−Voltage Plug (MVP) Connection
Selecting Plug
2
1
3
4
5
!
6
Do not cut off power cord connector and rewire. The power
cord connector and plugs will
work with standard NEMA receptacles. Modifying power
cord, connector, and plugs will
void product warranty.
7
Connecting Plug To Power Cord
Selecting Plug
4
1
5
Power Cord Connector From
Welding Power Source
Select plug for power supply receptacle
available at site. Not all plugs shown are
provided as standard with unit.
2
Plug − NEMA Type 5−15P
3
Receptacle − NEMA Type 5−15R
(Customer Supplied)
6
7
!
Plug − NEMA Type 5−20P (Optional
Part No. 219259)
Receptacle − NEMA Type 5−20R
(Customer Supplied)
Plug − NEMA Type 6−50P
Receptacle − NEMA Type 6−50R
(Customer Supplied)
Follow electrical service guide for
230 VAC in Section 5-8. Do not use
plug rating to size branch circuit
protection.
Connecting Plug To Power Cord
Align arrow on plug with arrow on power
cord connector. Push together.
Tighten threaded collar. As threaded collar
is tightened, push plug onto adapter until
collar is completely tight.
Connect plug to receptacle.
MVP Plug1 2012−03 / Ref. 803812-C
OM-261726 Page 22
. A complete Parts List is available at www.MillerWelds.com
SECTION 6 − OPERATION
6-1. Syncrowave 210 Controls
3
4
1
5
2
6
8
7
268890-B/ 805521-A
1
Amperage Adjustment Control
Use control to change preset amperage
value. If a remote control is used, preset
amperage value is the maximum amperage
output available. This control also functions
as a parameter change control while in the
menu mode (see Sections 6-2 thru 6-7).
2
Memory Card Port And Indicator
This port is used to add features to the machine and update software to the boards
within the machine. Indicator is lit while card
is being accessed.
3
Volt Meter
Displays actual voltage when voltage is
present at the weld output terminals. It is
also used to display parameter descriptions while in the menu.
4
Ammeter
Displays actual amperage while welding
and preset amperage while idle. It is also
used to display parameter selection options while in the menu.
5
Menu Button
Press button to scroll through available
parameters for the selected process. Hold
button to enter set-up mode (see Sections
6-2 thru 6-7).
6
Output ON Indicator
Blue indicator illuminates when output is
on.
7
Process Selector
Use to select one of the following processes:
• AC TIG - Used for welding aluminum.
• DC TIG - (DCEN) Used for welding mild
and stainless steel.
• DC Stick - (DCEP) Used for welding
steels.
• MIG - (Optional Expansion)
8
Power Switch
The memory card port uses an SD
memory card.
SD Logo is a trademark of the 3C.
OM-261726 Page 23
. A complete Parts List is available at www.MillerWelds.com
6-2. Accessing Control Panel Menu: AC TIG
1
Menu Button
Press Menu button to cycle through
parameters that can be set.
2
3
4
2
3
4
1
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter
setting.
150A
AC.AV
BAL
150A
75%
FREQ
120H
PPS
OFF
*PRO−SET provides PROfessionally developed SETtings for the weld process.
To use PRO−SET, press the menu button
to display the parameter and adjust the
encoder until PRO−SET flashes on the
display. PRO−SET flashes one time and
reveals the professional setting for the
parameter.
OM-261726 Page 24
Amperage Control:
268890-B
Controls the average AC welding amperage output.
Limits the maximum output of a remote amperage
device.
[BAL] Balance Control:* (% EN)
Controls Oxide Cleaning
Increasing setting reduces oxide cleaning. Range is
60 to 80%. (See tips below)
[FREQ] Frequency Control:*
Increasing setting narrows arc width range 60 to 150
Hertz. (See tips below)
[PULS] Pulse Control:
Reduces heat input to minimize distortion and increase travel speed. Set PPS (pulses per second).
The range is OFF−50 PPS. The background amperage and peak amperage are not adjustable. Background amperage equals 25% of peak amperage.
Peak amperage time equals 40%.
TIP: AC Balance controls the cleaning
action. If floating black spots appear in the
puddle, the balance setting is too high.
Turn the balance down until puddle becomes clear.
TIP: AC Frequency controls the width of
the arc cone. For thin fillet welds (less
than 1/4 in.) set the frequency to 120 Hz.
This frequency setting provides a focused
stable arc and produces a narrow weld.
For outside corner or groove welds on
heavy material, a wide weld may be required. Lower the frequency to between
70 and100 Hz. This frequency setting produces a wider weld.
. A complete Parts List is available at www.MillerWelds.com
6-3. Accessing DC TIG Control Panel Menu
1
2
Press Menu button to cycle
through parameters that can
be set.
1
4
3
Menu Button
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust
parameter setting.
Amperage Control:
Controls the welding amperage output. Limits the maximum output of a remote amperage device.
[PULS] Pulse Control:
150A
Reduces heat input to minimize distortion and increase
travel speed. Set PPS (pulses
per second). The range is
OFF−150 PPS. The background amperage and peak
amperage are not adjustable.
Background amperage equals
25% of peak amperage. Peak
amperage time equals 40%.
PPS
OFF
268890-B
6-4. Accessing DC Stick Control Panel Menu
1
2
4
3
1
Menu Button
Press Menu button to cycle
through parameters that can be
set.
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
150A
Amperage Control:
Controls the welding amperage output. Limits the maximum output of a
remote amperage device.
[DIG] Arc Force Control:
Controls the amount of additional
amperage at low voltage (short arc
length) conditions. Adjust the force
of the arc for different joint configurations and electrodes. Range is
OFF−100%.
DIG
30%
268890-B
OM-261726 Page 25
. A complete Parts List is available at www.MillerWelds.com
6-5. Accessing Spool Gun Control Panel Menu
1
Menu Button
Press Menu button to cycle through
parameters that can be set.
2
3
4
1
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter
setting.
14.0V
Voltage Control:
Controls the welding voltage output.
[WFS] Wire Feed Speed:
Controls the speed of the wire feed,
with a minimum of 0.0and a maximum
of 10.0.
WFS
Notes
OM-261726 Page 26
0.0
268890-B
. A complete Parts List is available at www.MillerWelds.com
6-6. Accessing User Setup Menu: AC And DC TIG
1
2
3
4
Menu Button
Press and hold Menu button for approximately two seconds to access machine configuration menus. Use Menu button to cycle
through parameters that can be set.
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
1
USER MENU
Arc Starting Method Selection:
STRT
RMT
TUNG
POST
HF
STD
3/32
AUTO
[STRT] [HF]
Is a non-contact starting method.
[STRT] [Lift]
Is a contact starting method.
Remote Starting Method Selection:
Remote Starting Options for Lift Arc.
[RMT] [STD]
Standard Remote Control.
[Out] [On]
Output On.
Tungsten Diameter Selection:
Each tungsten size has preset starting
parameters specific to that diameter for optimized starting. Range is 0.040 in. to (1/8
in.) and 0.5 mm−3.2 mm.
Post Flow Control Selection:
[POST] [AUTO]
Controls the length of time gas flows after
welding stops. Range is AUTO, OFF − 50T
(seconds). AUTO calculates the time
based on the maximum amperage of each
welding cycle. The minimum time is 8
seconds. Auto = maximum amperage/10.
268890-B
OM-261726 Page 27
. A complete Parts List is available at www.MillerWelds.com
6-7. Accessing User DC Stick Setup Menu
1
Menu Button
Press and hold Menu button for approximately 2 seconds to access
machine configuration menus. Use
Menu button to cycle through parameters that can be set.
2
3
4
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter
setting.
USER MENU
OCV
NORM
1
Arc Starting Method Selection:
[OCV] [NORM]
Normal open circuit voltage for arc starting.
[OCV] [LOW]
Low open circuit voltage for arc starting.
268890-B
OM-261726 Page 28
. A complete Parts List is available at www.MillerWelds.com
6-8. Accessing User Spool Gun Setup Menu
1
2
3
4
Menu Button
Press and hold Menu button for approximately two seconds to access
machine configuration menus. Use
Menu button to cycle through parameters that can be set.
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
USER
MENU
150A
150A
1
GUN
PROC
WIRE
MAT
S150
C25
0.030
18 GA
Spool Gun Selection:
[Gun] [S100]
[Gun] [S150]
Spool Gun
Selection:
Wire
Diameter
[Wire] [0.024]
[Wire] [0.030]
[Wire] [0.035]
Spool Gun Material Thickness
Selection:
[MAT] [24GA] / [22GA] / [20GA]
[MAT] [18GA] / [16GA] / [14GA]
[MAT] [1/8] / [3/16] / [1/4] [5/16]
[MAT] [3/8]
Spool Gun Process Selection:
[PROC] [FLUX]
[PROC] [TRI]
[PROC] [C25]
[PROC] [C100]
[PROC] [4043]
[PROC] [5356]
268890-B
OM-261726 Page 29
. A complete Parts List is available at www.MillerWelds.com
SECTION 7 − ADVANCED MENU FUNCTIONS
7-1. Accessing Tech Menu
1
2
3
1
4
Menu Button
Press and hold Menu button for approximately 4 seconds to scroll
past User Menu to Tech Menu. Use
Menu button to cycle through parameters that can be set.
2
3
4
Parameter Display
Setting Display
Encoder
Rotate Encoder to adjust parameter setting.
TECH
MENU
To exit user menu, press and hold
menu button approximately one
second, or turn power off.
. Settings in the Tech Menu are
global, meaning they may pertain to all or some of the process.
ARC
T/CY
MACH
RSET
LOW
0.0
HIGH
0.0
CAL
CAL
SOFT
SERL
268890-B
[ARC] [T/CY] Arc Timer: Monitors hours, minutes, and cycles of valid arc
on. To view, rotate encoder. To reset, rotate encoder until [RESET] [YES] is
displayed. Press Menu button to display [RESET] [Done]. Displays turn to
[000] [000].
[MACH] [Reset] Machine Reset:: Resets all machine values back to
factory defaults. To reset, turn encoder to [RESET] [YES]. Then press
Menu button. [RESET] [DONE] will be displayed when the reset is complete and factory defaults have been restored.
[CAL] [LOW] Calibrate Low: Calibrates low drive roll speed to provide
consistent wire feed speed between various spools of wire and spool
guns. To calibrate, press and hold the trigger, allowing the wire to feed until
it stops. Then measure the wire, and subtract from 24 (24−wire length =
Cal Low.
. The Wire Feed Speed does not adjust in the Tech Menu, but does adjust
in the Weld Process.
[CAL] [HIGH] Calibrate High: Calibrates high drive roll speed to provide
consistent wire feed speed between various spools of wire and spool
guns. To calibrate, press and hold the trigger, allowing the wire to feed until
it stops. Then measure the wire, and subtract from 24 (24−wire length =
Cal High.
NUM
. The Wire Feed Speed does not adjust in the Tech Menu, but does adjust
NUM
[SOFT] [NUM] Software Number: Use encoder to select desired board
to read software version and number.
in the Weld Process.
[SERL] [NUM] / [NA] Serial Number: This feature has not been implemented.
OM-261726 Page 30
. A complete Parts List is available at www.MillerWelds.com
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING
8-1. Routine Maintenance
!
Disconnect power before maintaining.
. Maintain more often during severe conditions.
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Δ = Repair
l = Replace
Every
3
Months
nl Labels
n l Gas Hoses
Every
3
Months
nΔ lCables And Cords
Every
6
Months
~:Durning heavy service, clean monthly.
8-2. Circuit Breaker CB1
1
Supplementary Protector CB1
If CB1 opens, unit will be completely
inoperative.
If CB1 opens repeatedly, have a Factory Authorized Service Agent check
unit..
1
805521-A
OM-261726 Page 31
. A complete Parts List is available at www.MillerWelds.com
8-3. Meter Troubleshooting Displays
1
RELE
. All directions are
1
ASE
.... TRIG
2 Sec
in reference to the
front of the unit. All circuitry referred to
is located inside the unit.
Over Temperature Errors:
Typical meter display may be in
several segments. Each segment is
shown for two seconds, and then
scrolls to the remaining segments
of the display. The message then
repeats itself.
Over temperature condition in the primary
inverter circuitry has occurred. Error will
clear after the temperature has reached acceptable levels.
Release Trigger Error:
w [RELE] [ASE]/[TRIG] [GER]
Remote 14 receptacle contactor control
(Pins A−B) must be opened before proceeding.
Communication Errors:
w [SCOM] [SD]
Serial Communication to the memory card
board has been lost. To clear error, turn off
power. If error does not clear or happens
frequently, contact a Factory Authorized
Service Agent.
w [INV] [OT]
w [PFC] [OT]
Over temperature condition in the primary
power factor correction circuitry has occurred. Error will clear after the temperature
has reached acceptable levels.
w [SEC] [OT]
Over temperature of the weld output circuitry has occurred. Error will clear after the
temperature has reached acceptable
levels.
Temperature Sensor Failure:
w [SCOM] [UI]
w [INV] [ERRT]
Serial Communication to the user interface
card board has been lost. To clear error, turn
off power. If error does not clear or happens
frequently, contact a Factory Authorized
Service Agent.
Indicates a short or open in the thermal protection circuitry located in the primary inverter circuitry of the unit. Contact a Factory
Authorized Service Agent if this display is
shown.
OM-261726 Page 32
GER
Repeat
w [PFC] [ERRT]
Indicates a short or open in the thermal protection circuitry located in the primary power factor correction circuitry of the unit. Contact a Factory Authorized Service Agent if
this display is shown.
w [SEC] [ERRT]
Indicates a short or open in the thermal protection circuitry located in the weld output
circuitry of the unit. Contact a Factory Authorized Service Agent if this display is
shown.
Latching Errors:
w [CLMP] [ERR]/[OVER] [VOLT]
Secondary clamp voltage too high.
Straighten out or shorten weld cables. If this
does not correct the problem, contact a
Factory Authorized Service Agent.
w [CLMP] [ERR]/[OVER] [AMPS]
Secondary clamp amperage too high.
Straighten out or shorten weld cables. If this
does not correct the problem, contact a
Factory Authorized Service Agent.
Not Valid Error:
w [Not] [Valid]
Indicates a non-allowable set-up on the
front panel.
. A complete Parts List is available at www.MillerWelds.com
8-4. Troubleshooting
. 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.
Trouble
Remedy
No weld output; unit completely
inoperative.
Place machine power switch in On position (see Section 6-1).
Place line disconnect switch in On position (see Section 5-11).
Check and replace line fuse(s), if necessary (see Section 5-11).
Check for proper input power connections (see Section 5-11).
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.
Make sure Material Amperage control is in proper position (see Section 6-1).
Erratic or improper weld output.
Lay weld cables out straight, do not leave weld cables coiled.
Have Factory Authorized Service Agent check unit.
Check position of Process Selector switch (see Section Figure 6-1).
Check position of Amperage control (see Section 6-1).
No control of weld output.
Make sure Material Amperage control is in proper position (see Section 6-1).
Lack of high frequency; difficulty in
starting GTAW arc.
Select proper size tungsten (see Section 11-1).
Be sure torch cable is not close to any grounded metal.
Check cables and torch for cracked insulation or bad connections. Repair or replace.
Wandering arc − poor control of
direction of arc.
Reduce gas flow rate (see Section 5-3).
Select proper size tungsten (see Section 11-1).
Properly prepare tungsten (see Section 11).
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Check and tighten all gas fittings.
Properly prepare tungsten (see Section 11).
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 5-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11).
Check for proper input power connections (see Section 5-10 or 5-11).
No weld output; fan on.
Check connection to remote control receptacle (see Section 5-2).
Check remote control (see remote control Owner’s Manual).
Unit overheated. Allow unit to cool (see Section 4-5).
Check for and remove anything blocking fan movement.
Fan not operating; weld output
available.
Have Factory Authorized Service Agent check fan motor.
Error message
displayed.
[SCOM]
[SD]
is Contact a Factory Authorized Service Agent.
Error message
displayed.
[SCOM]
[UI]
is Contact a Factory Authorized Service Agent.
OM-261726 Page 33
. A complete Parts List is available at www.MillerWelds.com
Trouble
Remedy
Error message
displayed.
[INV]
[ERRT]
is Contact a Factory Authorized Service Agent.
Error message
displayed.
[PFC]
[ERRT]
is Contact a Factory Authorized Service Agent.
Error message
displayed.
[SEC]
[ERRT]
is Contact a Factory Authorized Service Agent.
Error message [CLMP] [ERR] [OVER] Contact a Factory Authorized Service Agent.
[VOLT] is displayed.
Error message [CLMP] [ERR] [OVER] Contact a Factory Authorized Service Agent.
[AMPS] is displayed.
OM-261726 Page 34
. A complete Parts List is available at www.MillerWelds.com
Notes
OM-261726 Page 35
. A complete Parts List is available at www.MillerWelds.com
SECTION 9 − ELECTRICAL DIAGRAMS
262672-D
Figure 9-1. Circuit Diagram
OM-261726 Page 36
SECTION 10 − HIGH FREQUENCY
10-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
Work
TIG
high_freq 5/10 − S-0693
10-2. Installation Showing Possible Sources Of HF Interference
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
5
6
Best Practices
Not Followed
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
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
OM-261726 Page 37
10-3. Recommended Installation To Reduce HF Interference
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece if
required by
codes.
9
Best Practices Followed
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case (clean paint
from around hole in case, and use case
screw), work output terminal, line disconnect device, input supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
OM-261726 Page 38
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in. (6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
SECTION 11 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2016-10
Whenever possible and practical, use DC weld output instead of AC weld output.
11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
Unbalanced Wave
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceriated, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (.25 mm)
Up to 15
Up to 15
.020 in. (.50 mm)
5-20
5-20
.040 in. (1 mm)
15-80
15-80
1/16 in. (1.6 mm)
70-150
70-150
3/32 in. (2.4 mm)
150-250
140-235
1/8 in. (3.2 mm)
250-400
225-325
5/32 in. (4.0 mm)
400-500
300-400
3/16 in (4.8 mm)
500-750
400-500
1/4 in. (6.4 mm)
750-1000
500-630
♦Typical argon shielding gas flow rates are 10 to 25 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS).
11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
1
Radial Grinding
Causes Wandering Arc
1-1/2 To 4 Times
Electrode Diameter
2
Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
2
Tungsten Electrode
A 2% ceriated tungsten is recommended.
4
3
15° to 30°
3
Ideal Grind Angle Range: 15° to 30°
. 30 degrees is the recommended electrode grind angle.
1
Wrong Tungsten
Preparation
4
Straight Ground
Grind lengthwise, not radial.
Ideal Tungsten Preparation − Stable Arc
OM-261726 Page 39
SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW)
12-1. Positioning The Torch
!
Grinding the tungsten electrode
produces dust and flying sparks
which can cause injury and start
fires. Use local exhaust (forced
ventilation) at the grinder or wear
an approved respirator. Read
MSDS for safety information.
Consider using cerium or lanthanum based tungsten instead of
thoriated. Thorium dust contains
low-level radioactive material.
Properly dispose of grinder dust
in an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
1
Workpiece
3
2
4
90°
Make sure workpiece is clean before
welding.
1
2
Work Clamp
Place as close to the weld as possible.
3
4
5
6
10−15°
4
5
6
10−25°
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten according
to Section 11.
Guidelines:
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate
shielding gas coverage. (For example,
if tungsten is 1/16 in. diameter, gas cup
should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the
tungsten extends out gas cup of torch.
1/16 in.
3/16 in.
Bottom View Of Gas Cup
The tungsten extension should be no
greater than the inside diameter of the
gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref. ST-161 892
OM-261726 Page 40
12-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
15°
Tilt torch
Remove rod
Add filler metal
Move torch to front
of pool. Repeat process.
ST-162 002-B
12-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20°
90°
70°
75°
20°
10°
15°
Corner Joint
Lap Joint
20-40°
90°
75°
75°
15°
15°
30°
ST-162 003 / S-0792
OM-261726 Page 41
SECTION 13 − STICK WELDING (SMAW) GUIDELINES
13-1. Stick Welding Procedure
!
Weld current starts when
electrode touches workpiece.
!
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.
Equipment Needed:
Tools Needed:
. Always wear appropriate per1
sonal protective clothing.
Workpiece
Make sure workpiece is clean before welding.
2
Constant Current
Welding Power Source
5
2
3
6
7
3
Electrode
Before striking an arc, insert an
electrode in the electrode holder. A
small diameter electrode requires
less current than a large one. Follow recommendations of the electrode manufacturer when setting
weld amperage (see Section
13-2).
4
1
Work Clamp
Place as close to the weld as
possible.
4
Insulated Electrode Holder
5
Electrode Holder Position
6
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. Correct
arc length is related to electrode diameter. Examine the weld bead to
determine if the arc length is correct.
Arc length for 1/16 and 3/32 in. diameter electrodes should be about
1/16 in. (1.6 mm); arc length for 1/8
and 5/32 in. electrodes should be
about 1/8 in. (3 mm).
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
stick 2016 - 10 − 151 593
OM-261726 Page 42
7014
7018
7024
Ni-Cl
308L
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
DEEP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
MED
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
FLAT
HORIZ*
LOW
SMOOTH, EASY,
FASTER
NI-CL
EP
ALL
LOW
CAST IRON
308L
EP
ALL
LOW
STAINLESS
USAGE
ALL
EP
AC
EP
6011
DC*
6010
ELECTRODE
450
400
350
300
AMPERAGE
RANGE
250
200
150
PENETRATION
6013
POSITION
6010
&
6011
100
50
DIAMETER
ELECTRODE
13-2. Electrode and Amperage Selection Chart
MIN. PREP, ROUGH
HIGH SPATTER
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
13-3. Striking an Arc
1
!
Weld current starts when electrode touches workpiece.
1
2
3
Electrode
Workpiece
Arc
Scratch Technique
2
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out,
electrode was lifted too high. If electrode sticks to workpiece, use a quick
twist to free it.
Tapping Technique
3
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.
1
2
3
S-0049 / S-0050
OM-261726 Page 43
13-4. Positioning Electrode Holder
1
2
After learning to start and hold
an arc, practice running beads
of weld metal on flat plates using
a full electrode.
1
10°-30°
90°
End View Of Work Angle
Side View Of Electrode
Angle
Hold the electrode nearly perpendicular to the work, although
tilting it ahead (in the direction of
travel) will be helpful.
2
90°
. To produce the best results,
hold a short arc, travel at a
uniform speed, and feed the
electrode downward at a
constant rate as it melts.
Groove Welds
10°-30°
45°
1
2
45°
Fillet Welds
S-0060
13-5. Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
2
3
5
1
S-0053-A
13-6. Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
2
3
4
5
4
5
No Overlap
Good Penetration into Base
Metal
1
S-0052-B
OM-261726 Page 44
13-7. Conditions That Affect Weld Bead Shape
. Weld bead shape is affected
by
electrode angle,
arc
length, travel speed, and thickness of base metal.
Angle Too Small
Correct Angle
10° - 30°
Angle Too Large
Electrode Angle
Drag
Spatter
Arc Length
Too Short
Normal
Too Long
Slow
Normal
Fast
Travel Speed
S-0061
13-8. Electrode Movement During Welding
. Normally,
2
1
1
2
3
3
a single stringer
bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple
stringer beads work better.
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side to Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a
wide area in one pass of the electrode. Do not let weave width exceed 2-1/2 times diameter of
electrode.
S-0054-A
13-9. Welding Lap Joints
1
2
Electrode
Single-Layer Fillet Weld
Move electrode in circular motion.
30°
Or Less
30°
Or Less
1
1
2
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
S-0063 / S-0064
OM-261726 Page 45
13-10. Welding Groove (Butt) Joints
1
Tack Welds
Prevent butt joint distortion by tack
welding the materials in position
before final weld.
Workpiece distortion occurs when
heat is applied locally to a joint.
One side of a metal plate will “curl”
up toward the weld. Distortion will
also cause the edges of a butt joint
to pull together ahead of the electrode as the weld cools.
1
2
1/16 in.
(1.6 mm)
Square Groove Weld
3
Single V-Groove Weld
4
Double V-Groove Weld
Materials up to 3/16 in. (5 mm)
thick can often be welded without
special preparation using the
square groove weld. However,
when welding thicker materials it
may be necessary to prepare the
edges (V-groove) of butt joints to
ensure good welds.
30°
The single or double V-groove
weld is good for materials 3/16 −
3/4 in. (5-19 mm) thick. Generally,
the single V-groove is used on materials up to 3/4 in. (19 mm) thick
and when, regardless of thickness,
you can weld from one side only.
Create a 30 degree bevel with oxyacetylene or plasma cutting equipment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
4
3
2
S-0062
13-11. Welding Tee Joints
1
2
Electrode
Fillet Weld
Keep arc short and move at definite rate of speed. Hold electrode
as shown to provide fusion into the
corner. Square edge of the weld
surface.
For maximum strength weld both
sides of upright section.
3
1
2
45°
Or
Less
1
2
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
13-8. Remove slag before making
another weld pass.
3
S-0060 / S-0058-A / S-0061
OM-261726 Page 46
13-12. Weld Test
1
2
3
Strike the weld joint in the direction shown. A good weld
bends over but does not break.
3
If the weld breaks, examine it to determine the cause.
If the weld is porous (many holes), the arc length was
probably too long.
3
If the weld contains bits of slag, the arc may have been
too long or the electrode was moved incorrectly which
allowed molten slag to be trapped in the weld. This may
happen on a V-groove joint made in several layers and
calls for additional cleaning between layers.
2 To 3 in.
(51-76 mm)
1/4 in.
(6.4 mm)
Vise
Weld Joint
Hammer
2
1
2 To 3 in.
(51-76 mm)
2
1
If the original beveled surface is visible the material was
not fully melted which is often caused by insufficient
heat or too fast a travel speed.
S-0057-B
13-13. Troubleshooting
Porosity − small cavities or holes resulting from gas pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding
weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
OM-261726 Page 47
Lack Of Penetration − shallow fusion between weld metal and base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
Possible Causes
Corrective Actions
Unsteady hand.
Use two hands. Practice technique.
Distortion − contraction of weld metal during welding that forces base metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Corrective Actions
Excessive heat input.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-261726 Page 48
Effective January 1, 2017
(Equipment with a serial number preface of MH or newer)
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.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective date of
6.
90
Days — Parts
this limited warranty is free of defects in material and workmanship at
* Accessory (Kits)
the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,
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INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
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FITNESS.
Non-Electronic Controls
Within the warranty periods listed below, Miller will repair or replace any
* M-Guns
warranted parts or components that fail due to such defects in material
* MIG Guns, Subarc (SAW) Torches, and External
or workmanship. Miller must be notified in writing within thirty (30) days
Cladding Heads
of such defect or failure, at which time Miller will provide instructions on
*
Remote
Controls and RFCS-RJ45
the warranty claim procedures to be followed. If notification is submitted
* Replacement Parts (No labor)
as an online warranty claim, the claim must include a detailed
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description of the fault and the troubleshooting steps taken to identify
failed components and the cause of their failure.
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 delivery date of the equipment to the
original end-user purchaser, and not to exceed twelve months after the
equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
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Series) (No Labor)
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(NOTE: Engines are Warranted Separately by the
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2 Years — Parts and Labor
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(No Labor)
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Collector Series
1 Year — Parts and Labor Unless Specified
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* CoolBelt and CoolBand Blower Unit (No Labor)
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* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
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* HF Units
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(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)
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Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
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.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
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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
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TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
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INCIDENTAL
OR
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WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
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ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
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BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
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FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
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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 2017-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
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)
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and Parts)
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For International Locations Visit
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Welding Process Handbooks
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Contact the Delivering Carrier to:
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For assistance in filing or settling claims, contact
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ORIGINAL INSTRUCTIONS − PRINTED IN USA
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© 2017 Miller Electric Mfg. Co.
2017−01