Miller | MD310828L | Owner Manual | Miller SYNCROWAVE 350 LX User manual

Miller SYNCROWAVE 350 LX User manual
OM-363
213117AQ
2013−08
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
Syncrowave 250 DX / 350 LX
With Optional Running Gear And Cooler
Visit our website at
www.MillerWelds.com
File: TIG (GTAW)
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2.
1-3.
1-4.
1
1
Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
5
2-1.
2-2.
2-3.
Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
5
5
7
2-4.
2-5.
2-6.
Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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9
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SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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11
13
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Important Information Regarding IEC Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
14
15
3-4.
3-5.
3-6.
Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooler Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Power Source Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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16
16
3-7.
3-8.
3-9.
Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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19
20
3-10. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Shielding Gas Connections And 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. TIG Connections With A Two-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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21
22
3-13. TIG Connections With A One-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) . . . . . . . . . . . . .
3-15. Front Panel Display For TIG AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
23
24
3-16. Optional Cooler Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . .
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26
27
3-19. Front Panel Display For Stick AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-20. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-21. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
29
31
3-22. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls (350 LX Nameplates Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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34
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4-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
35
35
4-5.
4-6.
4-7.
Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4T, 4T Momentary, And Mini Logic Trigger Operation (Requires Optional Sequence Controls) . . . . . .
Reconfiguring Trigger Hold For 4T And Mini Logic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
38
40
4-8. Selecting TIG Starting Characteristics Using Syncro-Start Technology . . . . . . . . . . . . . . . . . . . . . . .
4-9. Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
4-10. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Preflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models) . . . . . . . . . . . . . . . . . . . . .
4-13. Sequence Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Initial Time Control And Initial Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Final Slope Control And Final Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Spot Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Welding Power Source Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Supplementary Protector CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Routine Maintenance For Optional Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting The Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Troubleshooting The Optional Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . .
11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . . .
11-2. Preparing Tungsten Electrode For Welding With Phase Control Machines . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
FOR ADDITIONAL WELDING INFORMATION AND RESOURCES, VISIT: www.MillerWelds.com
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
7
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.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
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!
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-363 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not 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.
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).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on 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).
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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.
Do not use welder to thaw frozen pipes.
OM-363 Page 2
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
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.
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.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
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.
BATTERY EXPLOSION can injure.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
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
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
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.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-363 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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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 30333 (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). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may 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-363 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_2011−10
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.
NOTE − 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.
Ne pas toucher aux pièces électriques sous tension.
Porter des gants isolants et des vêtements de protection secs et
sans trous.
S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
OM-363 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher à mains nues les parties
chaudes.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
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.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
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.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et 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 et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Porter un casque de soudage 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).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
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.
Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-363 Page 6
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).
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
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.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
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.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
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.
Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
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.
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.
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.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
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.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
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.
Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
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.
Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
OM-363 Page 7
Les PIÈCES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
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.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
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.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
Les PIÈCES MOBILES peuvent
causer des blessures.
S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
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.
Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
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.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
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)
OM-363 Page 8
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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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 30333 (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 de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des 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:
4. Maintenir la tête et le torse aussi loin que possible du matériel 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
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
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.
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.
OM-363 Page 9
OM-363 Page 10
A complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
OM-363 Page 11
A complete Parts List is available at www.MillerWelds.com
Do not remove or paint over (cover) the label.
Safe20 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
Notes
OM-363 Page 12
A complete Parts List is available at www.MillerWelds.com
3-2. Miscellaneous Symbols And Definitions
A
V
Amperes
Panel−Local
Gas Tungsten Arc
Welding (GTAW)
Shielded Metal Arc
Welding (SMAW)
Volts
Do Not Switch
While Welding
Arc Force (DIG)
Background Amps
Output
Circuit Breaker
Remote
Temperature
Protective Earth
(Ground)
Alternating Current
High Frequency Start
Water Input
Postflow Timer
Preflow Timer
High Frequency Continuous
Water Output
Gas (Supply)
Gas Output
Gas Input
Increase/Decrease
Of Quantity
On
Off
Percent
Direct Current
Balance Control
Maximum Cleaning
Maximum
Penetration (Minimum Cleaning)
Electrode Positive
Electrode
Negative
Final Slope
Meter
Single-Phase
U2
X
Conventional Load
Voltage
Line Connection
I1max
Rated Maximum
Supply Current
U0
Rated No Load
Voltage (Average)
U1
Primary Voltage
I1
Primary Current
I2
Rated Welding
Current
IP
Degree Of
Protection
I1eff
Maximum Effective
Supply Current
S
Up
Duty Cycle
1
1
Hz
Single-Phase
Combined AC/DC
Power Source
Hertz
Electrode
Work
Thickness Gauge
Spark Gap
Seconds
Final Amperage
Initial Time
Initial Amperage
Pulse Percent On
Time
Spot Time
Lift-Arc
Trigger Hold
Pulser On-Off
Pulse Frequency
4T
4 Step Trigger Operation Sequence
Input
Rated peak starting voltage
OM-363 Page 13
A complete Parts List is available at www.MillerWelds.com
SECTION 4 − INSTALLATION
4-1. Important Information Regarding IEC Products
A. Information On Compliance With Essential Requirements
This equipment conforms to the essential requirements and provisions of the stated Standard(s):
IEC 60974-1: 2005 Arc Welding Equipment − Welding Power Sources
IEC 60974-10: 2004 Arc Welding Equipment − Electromagnetic Compatibility Requirements
EN 50445 Product family standard to demonstrate compliance of equipment for resistance welding, arc welding and allied processes with
the basic restrictions related to human exposure to electromagnetic fields (0 Hz − 300 Hz) BS EN 50445:2008
B. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
4-2. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the front 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-363 Page 14
A complete Parts List is available at www.MillerWelds.com
4-3. Selecting A Location
Movement
1
OR
2
Location And Airflow
3
1
18 in.
(460 mm)
18 in. (460 mm)
Ref. 117 264-C / 803 584-C
!
Falling Unit Can Cause Injury.
Use lifting eye to lift unit only, NOT
running gear, gas cylinders, or any
other accessories.
1
2
If using lift forks to move unit, be sure
forks are long enough to extend
beyond opposite side of unit.
Lifting Eye
Lifting Forks
3
!
Special installation may be required
where gasoline or volatile liquids
are present − see NEC Article 511 or
CEC Section 20.
!
Do not move or operate unit where
it could tip.
Use lifting eye or lifting forks to move unit.
Use equipment of adequate capacity
to lift and support unit.
If using lifting forks, extend forks beyond
opposite side of unit.
Line Disconnect Device
Locate unit near correct input power supply.
OM-363 Page 15
A complete Parts List is available at www.MillerWelds.com
4-4. Dimensions And Weights
Dimensions
A
D
C
B
G
C
Front
E
Height
36-1/4 in. (921 mm)
Width
23 in. (584 mm)
Length
28 in. (711 mm)
A
25 in. (635 mm)
B
1-25/64 in. (35 mm)
C
1-5/8 in. (41 mm)
D
22 in. (559 mm)
E
20 in. (508 mm)
F
22-1/4 in. (565 mm)
G
1-1/8 in. (29 mm)
H
1/2 in. (13 mm) Dia
F
H
803 616-A
Weight
400 lbs (181 kg) For 250 DX Models
496 lbs (225 kg) For 350 LX Models
4-5. Cooler Specifications
Cooler Specifications
Cooler Tank Capacity
3 gal (11.4 L)
Coolant Flow Rate 1 liter per minute (1.1 quart)
Use With Torches Rated Up To 400 Amperes
4-6. Welding Power Source Specifications
A. For 350 LX Models
Rated
Welding
Output
Amperes Input at AC Balanced Rated Load Output,
50/60 Hz, Single-Phase
PFC
**
NEMA
Class I (60)
− 300
Amperes, 32
Volts AC,
60% Duty
Cycle
NEMA Class
II (40) − 350
Amperes, 34
Volts AC,
40% Duty
Cycle
200V 220V 230V 400V 440V 460V 520V 575V KVA
Amperage
Range
No
PFC
125
3.3*
103
2.2*
110
2.0*
57
1.5*
52
1.2*
55
1.7*
43
1.0*
42
1.1*
25.0
0.9*
10.6
0.6*
With
PFC
92
77*
77
67*
78
69*
40
36*
39
33*
38
34*
33
28*
31
27.2*
18.0
16.6*
10.5
0.6*
15 KV
No
PFC
146
3.3*
120
2.2*
128
2.6*
66
2.5*
60
1.2*
65
1.7*
51
1.0*
50
1.1*
29.5
0.9*
13.7
0.4*
15 KV
With
PFC
114
77*
95
67*
94
69*
49
36*
47
33*
47
34*
40
28*
38
27.2*
21.7
16.6*
13.3
0.6*
15 KV
3 − 400A
3 − 400A
*While idling
**Power Factor Correction
Arc striking device is designed for manual guided operations
OM-363 Page 16
KW
Rated
Peak
Max Starting
OCV Voltage
(Up)
(Uo)
80V
80V
15 KV
A complete Parts List is available at www.MillerWelds.com
B. For 250 DX Models
Amperes Input at AC Balanced Rated
Load Output, 60 Hz, Single-Phase
Rated
Welding
Output
PFC
**
200V
NEMA Class
I (40) − 200
Amperes, 28
Volts AC,
60% Duty
Cycle
No
PFC
88
77
*3.3
*2.8
With
PFC
60
52
*55.3
*49.5
NEMA Class
II (40) − 250
Amperes, 30
Volts AC,
40% Duty
Cycle
No
PFC
110
96
*3.3
*2.8
With
PFC
82
71
*55.3
*49.5
230V
460V
575V
KVA
38
31
17.6
8.6
*1.5
*1.1
*.59
*.29
26
21
12.06
8.11
*24.5
*19.6
*11.2
*.39
48
38
21.98
11.76
*1.5
*1.1
*.59
*.29
35
28
16.32
11.81
*24.5
*19.6
*11.2
*1.93
KW
Amperage
Range
Max
OCV
(Uo)
Rated
Peak
Starting
Voltage
(Up)
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
Amperage
Range
Max
OCV
(Uo)
Rated
Peak
Starting
Voltage
(Up)
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
Amperage
Range
Max
OCV
(Uo)
Rated
Peak
Starting
Voltage
(Up)
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
3 − 310A
80V
15 KV
*While idling
**Power Factor Correction
Arc striking device is designed for manual guided operations
Amperes Input at AC Balanced Rated
Load Output, 50/60 Hz, Single-Phase
Rated
Welding
Output
PFC
**
220V
NEMA Class
I (40) − 200
Amperes, 28
Volts AC,
60% Duty
Cycle
No
PFC
82
45
*3.0
*1.6
With
PFC
61
34
*45.9
*25.1
NEMA Class
II (40) − 250
Amperes, 30
Volts AC,
40% Duty
Cycle
No
PFC
100
55
*3.0
*1.6
81
44
*45.9
*25.1
With
PFC
400V
440V
520V
KVA
41
35
17.6
8.6
*1.4
*1.2
*.59
*.29
31
26
12.06
8.11
*22.8
*23.2
*11.2
*.39
50
42
21.98
11.76
*1.4
*1.2
*.59
*.29
40
34
16.32
11.81
*22.8
*23.2
*11.2
*1.93
KW
*While idling
**Power Factor Correction
Arc striking device is designed for manual guided operations
Amperes Input at AC Balanced Rated
Load Output, 50 Hz, Single-Phase
Rated
Welding
Output
PFC
**
200V
NEMA Class
I (40) − 175
Amperes, 27
Volts AC,
60% Duty
Cycle
No
PFC
80
69
*3.3
*2.8
With
PFC
52
45
22
18
10.3
7.3
*55.3
*49.5
*24.5
*19.6
*11.2
*.39
NEMA Class
II (40) − 225
Amperes, 29
Volts AC,
40% Duty
Cycle
No
PFC
101
88
44
35
20.2
10.2
*3.3
*2.8
*1.5
*1.1
*.59
*.29
With
PFC
74
64
32
26
14.7
10.1
*55.3
*49.5
*24.5
*19.6
*11.2
*1.93
230V
460V
575V
KVA
35
28
15.9
7.4
*1.5
*1.1
*.59
*.29
KW
*While idling
**Power Factor Correction
Arc striking device is designed for manual guided operations
OM-363 Page 17
A complete Parts List is available at www.MillerWelds.com
4-7. Duty Cycle And Overheating
Duty Cycle is the percentage of 10
minutes that the unit can weld at rated
load without overheating.
If unit overheats, output stops, front
panel voltmeter/ammeter displays a
HLP3 or HLP5 message (see Section
7-1), and cooling fans run. Wait fifteen
minutes for unit to cool. Reduce amperage or duty cycle before welding.
250 DX Models
NOTICE − Exceeding duty cycle can
damage unit and void warranty.
40% Duty Cycle At 250 Amperes
4 Minutes Welding
60% Duty Cycle At 200 Amperes
6 Minutes Resting
6 Minutes Welding
4 Minutes Resting
Overheating
A
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 / Ref. 116 198
350 LX Models
40% Duty Cycle At 350 Amperes
4 Minutes Welding
Overheating
60% Duty Cycle At 300 Amperes
6 Minutes Welding
6 Minutes Resting
4 Minutes Resting
A
0
15
Minutes
OM-363 Page 18
OR
Reduce Duty Cycle
duty1 4/95 / 190 276
A complete Parts List is available at www.MillerWelds.com
4-8. Volt-Ampere Curves
A. For 250 DX Models
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
10
0
0
0
50
100
150
200
250
300
350
400
450
0
50
AMPS
100
150
200
250
300
350
400
450
AMPS
205 631 / 205 632
B. For 350 LX Models
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
350 Amperes Models
ssb1.1 10/91 − ST-190 277 / ST-190 278
OM-363 Page 19
A complete Parts List is available at www.MillerWelds.com
4-9. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Select weld cable sizes for pulsing applications at peak amperage value.
Weld Cable Size** and Total Cable (Copper) Length in
Weld Circuit Not Exceeding***
Weld Output
Terminals
!
Turn off power before connecting to weld output terminals.
!
Do not use worn, damaged, undersized, or poorly spliced
cables.
100 ft (30 m) or Less****
Work
Ref. 803 588-B
* This
200 ft
(60 m)
10 − 60% Duty
Cycle
60 − 100% Duty
Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
150
3 (30)
3 (30)
2 (35)
1 (50)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
Welding
Amperes***
Electrode
150 ft
(45 m)
10 − 100% Duty Cycle
AWG (mm2)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
*** Select weld cable size for pulsing application at peak amperage value.
****For distances longer than 100 ft (30 m) and up to 200 ft (60 m), use direct current (DC) output only. For distances longer than those shown
in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-J 2011−07 (TIG)
Notes
OM-363 Page 20
A complete Parts List is available at www.MillerWelds.com
4-10. Remote 14 Receptacle Information
!
Socket*
Turn off power before
connecting to receptacle.
A
Contactor control +15 volts DC.
B
Contact closure to A completes +15 volts DC
contactor control circuit and enables output.
C
Output to remote control; 0 to +10 volts DC output
to remote control.
REMOTE
OUTPUT
CONTROL
D
Remote control/feedback circuit common.
E
0 to +10 volts DC input command signal from
remote control.
A/V
F
Current feedback; +1 volt DC per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt DC per 10 volts output.
CHASSIS
K
Chassis common.
G
Common for +15 volts DC socket A.
24 VOLTS DC
A
B
J
K
OUTPUT
CONTACTOR
I
H
C L N
D M
G
E F
A
Ref. 803 588-B
Socket Information
GND
*The remaining sockets are not used.
4-11. Shielding Gas Connections And 115 Volts AC Cooler Receptacle
4
!
Turn Off power before connecting to receptacle.
1
Gas Valve In Connection
Located on rear of unit.
2
3
5
Gas Valve Out Connection
Connections have 5/8-18 righthand threads.
3
Cylinder Valve
Open valve slightly so gas flow
blows dirt from valve. Close valve.
Tools Needed:
5/8, 3/4, 1-1/8 in.
4
Regulator/Flow Gauge
Connect regulator/flow gauge to
gas cylinder.
Connect customer supplied gas
hose between regulator/flow gauge
and gas in fitting.
5
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour).
6
115 V 15 Amp AC Cooler
Receptacle
Receptacle is protected from overload by circuit breaker CB1 (see
Section 6-2).
RC2 is a designated use re-
2
ceptacle intended only for supplying AC power to a Miller-approved cooler.
Rear View
Front View
6
1
Ref. 803 588-B / Ref. 803 585-C / Ref. 157 858
OM-363 Page 21
A complete Parts List is available at www.MillerWelds.com
4-12. TIG Connections With A Two-Piece Air-Cooled Torch
!
Turn Off power before making
connections.
1
Gas-In Connection
Connect gas hose from gas supply to
gas-in connection.
2
2
Output Selector Switch (See
Section 5-2)
Switch is shown in DCEN (direct current electrode negative) position for
TIG HF Impulse DCEN welding. For
front panel control display, see Section
4-14. For TIG AC welding, place switch
in AC position (see Section 5-2). For
TIG AC front panel control display, see
Section 4-15.
5
6
3
1
3
Work Weld Output Terminal
Connect work lead to work weld output
terminal.
4
4
Remote 14 Receptacle
Connect desired remote control to Remote 14 receptacle (see Section 4-10).
Tools Needed:
11/16 in., (21 mm)
5
Electrode Weld Output Terminal
Connect TIG torch to electrode weld
output terminal.
6
Gas-Out Connection
Connect torch gas hose to gas-out
fitting.
803 586-D
4-13. TIG Connections With A One-Piece Air-Cooled Torch
!
Turn Off power before making
connections.
1
Gas-In Connection
Connect gas hose from gas supply to
gas−in connection.
2
2
Output Selector Switch (See
Section 5-2)
Switch is shown in DCEN (direct current electrode negative) position for
TIG HF Impulse DCEN welding. For
front panel control display, see Section
4-14. For TIG AC welding, place switch
in AC position (see Section 5-2). For
TIG AC front panel control display, see
Section 4-15.
5
6
3
3
1
Work Weld Output Terminal
Connect work lead to work weld output
terminal.
4
Remote 14 Receptacle
Connect desired remote control to Remote 14 receptacle (see Section 4-10).
4
5
Tools Needed:
11/16 in., (21 mm)
Electrode Weld Output Terminal
Connect TIG torch to electrode weld
output terminal.
6
Gas-Out Connection
Connect torch gas hose to gas-out
fitting.
803 615-C
OM-363 Page 22
A complete Parts List is available at www.MillerWelds.com
4-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative)
1
Front Panel
Correct front panel display for basic TIG HF Impulse DCEN
welding.
For all front panel switch pad
controls: press switch pad to
turn on light and enable
function.
Green on nameplate indicates a
TIG function (see Section 5-1 for
description of controls).
1
217 264 / 250 526
OM-363 Page 23
A complete Parts List is available at www.MillerWelds.com
4-15. Front Panel Display For TIG AC
1
Front Panel
Correct front panel display for
basic TIG AC welding.
For all front panel switch pad
controls: press switch pad to
turn on light and enable
function.
Green on nameplate indicates a
TIG function (see Section 5-1 for
description of controls).
1
OM-363 Page 24
A complete Parts List is available at www.MillerWelds.com
4-16.
Optional Cooler Connections
!
Disconnect cooler plug from
welding power source receptacle before filling.
1
Cap
Remove cap and fill tank with three
gallons of distilled or deionized water for operations above 32° F (0°
C), or three gallons of Miller coolant
part no. 043 810.
2
Gas Out Connection
Connect TIG torch gas hose to gas
out fitting.
3
5
4
Electrode Weld Output
Terminal
Connect TIG torch to electrode
weld output terminal.
8
3
4
2
Connect remote control to receptacle if desired.
7
1
6
5
Remote 14 Receptacle
Work Weld Output Terminal
Connect work lead to work weld
output terminal.
6
Water-In (From Torch)
Connection
Connect torch water-out (red) hose
to welding power source water-in
connection.
7
Water-Out (To Torch)
Connection
Connect torch water-in (blue) hose
to welding power source water-out
connection.
8
Cooler Power Cord
RC2 is a designated use re-
ceptacle intended only for supplying AC power to a Miller-approved cooler.
Connect plug to cooler receptacle
to provide power to the cooler.
Tools Needed:
GTAW Or Where
HF* Is Used
Application
3-1/2
Gal
11/16 in., (21 mm for IEC units)
Low Conductivity Coolant
No. 043 810**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protect to -37° F (-38° C) and resist algae growth.
NOTICE − Use of any coolant other than those listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.)
804 994-C
OM-363 Page 25
A complete Parts List is available at www.MillerWelds.com
4-17. Stick Connections
!
Turn Off power before making connections.
1
Work Weld Output Terminal
Connect work lead to work weld
output terminal.
2
Electrode Weld Output
Terminal
Connect electrode holder to electrode weld output terminal.
3
Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Section 4-10).
4
2
4
Output Selector Switch (See
Section 5-2)
Switch is shown in DCEP (direct
current electrode positive) position
for Stick DCEP welding. For front
panel control display, see Section
4-18. For Stick AC welding, place
switch in AC position. For Stick AC
front panel control display, see Section 4-19.
3
1
Tools Needed:
11/16 in., (21 mm), 3/4 in.
803 587-C
Notes
For additional welding information and resources, visit:
www.MillerWelds.com/resources/improving-your skills
OM-363 Page 26
A complete Parts List is available at www.MillerWelds.com
4-18. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
1
Front Panel
Correct front panel display for
basic Stick DCEP welding.
For all front panel switch pad
controls: press switch pad to
turn on light and enable
function.
Gray on nameplate indicates a
Stick function (see Section 5-1
for description of controls).
1
OM-363 Page 27
A complete Parts List is available at www.MillerWelds.com
4-19. Front Panel Display For Stick AC
1
Front Panel
Correct front panel display for
basic Stick AC welding.
For all front panel switch pad
controls: press switch pad to
turn on light and enable
function.
Gray on nameplate indicates a
Stick function (see Section 5-1
for description of controls).
1
OM-363 Page 28
A complete Parts List is available at www.MillerWelds.com
4-20. Electrical Service Guide
A. For 250 DX Models
Input amperage may be higher than shown in table when Balance Control is in an unbalanced position.
All values in both tables were calculated at 60% duty cycle.
Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range,
damage to unit may occur.
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.
50/60 Hertz Models
Without Power Factor Correction
Input Voltage (V)
200
220
230
400
440
460
520
575
Input Amperes (A) At Rated Output
88
82
77
45
41
38
35
31
Time-Delay Fuse 2
125
125
125
70
60
60
50
45
Normal Operating (Fast) Fuse 3
125
125
125
70
60
60
50
45
4
6
6
8
8
10
10
10
167
(51)
137
(42)
153
(47)
305
(93)
369
(112)
281
(86)
352
(107)
439
(134)
6
6
6
8
10
10
10
10
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
Circuit Breaker 1
Min Input Conductor Size In
AWG4
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2011 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). 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.
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.
50/60 Hertz Models
With Power Factor Correction
Input Voltage (V)
200
220
230
400
440
460
520
575
Input Amperes (A) At Rated Output
60
61
52
34
31
26
26
21
Time-Delay Fuse 2
90
90
80
50
45
40
40
30
3
90
90
80
50
45
40
40
30
8
8
8
10
10
10
10
12
87 (26)
102
(31)
115
(35)
226
(69)
274
(84)
308
(94)
383
(117)
295
(90)
8
8
8
10
10
10
10
12
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
Circuit Breaker 1
Normal Operating (Fast) Fuse
Min Input Conductor Size In AWG4
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2011 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). 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-363 Page 29
A complete Parts List is available at www.MillerWelds.com
B. For 350 LX Models
Input amperage may be higher than shown in table when Balance Control is in an unbalanced position.
All values in both tables were calculated at 60% duty cycle.
Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in both tables. If actual input voltage is outside of this range,
damage to unit may occur.
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.
50/60 Hertz Models
Without Power Factor Correction
Input Voltage (V)
200
220
230
400
440
460
520
575
Input Amperes (A) At Rated Output
125
103
110
57
52
55
43
42
Time-Delay Fuse 2
150
125
125
70
70
60
60
50
Normal Operating (Fast) Fuse 3
175
175
175
90
90
80
70
70
3
3
4
8
8
8
8
8
151
(46)
182
(56)
171
(52)
246
(75)
298
(91)
326
(99)
416
(127)
509
(155)
6
6
6
8
8
8
8
8
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
Circuit Breaker 1
Min Input Conductor Size In AWG4
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2011 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). 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.
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.
50/60 Hertz Models
With Power Factor Correction
Input Voltage (V)
200
220
230
400
440
460
520
575
Input Amperes (A) At Rated Output
92
77
78
40
39
38
33
31
Time-Delay Fuse 2
110
100
90
50
50
45
40
35
Normal Operating (Fast) Fuse 3
125
125
125
70
60
60
50
45
4
6
6
8
8
8
10
10
145
(44)
119
(36)
130
(40)
263
(80)
318
(97)
347
(106)
300
(91)
367
(112)
6
6
6
8
10
10
10
10
Max Recommended Standard Fuse Or Circuit Breaker
Rating In Amperes
Circuit Breaker 1
Min Input Conductor Size In
AWG4
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG4
Reference: 2011 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). 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-363 Page 30
A complete Parts List is available at www.MillerWelds.com
4-21. Placing Jumper Links
Label found on 250 DX models with the following stock numbers:
907194, 907194-021 907194-031 and, 907194-032
Label found on 350 LX models with the following stock numbers:
907198, 907198-011, 907198-021, 907198-031 and 907198-032
2
!
Check input voltage available at
site.
1
1
Disconnect and lockout/tagout input power before
installing or moving jumper
links.
Jumper Link Label
Check label − only one label is on
unit.
2
083 566-F
Or
Label found on 250 DX models with the following stock numbers:
907195, 907195-021, 907195-031 and, 907195-032
Jumper Links
Move jumper links to match input
voltage.
Close and secure access door, or
go on to Section 4-22.
Label found on 350 LX models with the following stock numbers:
907199, 907199-021, 907199-031 and 907199-032
230 VOLTS
460 VOLTS
575 VOLTS
1
L
L
L
L
L
L
010 587-D
Or
Label found on 250 DX models with stock number 907408, and 907516
Label found on 350 LX models with stock number 907409, and 907517
1
191 440-A
Tools Needed:
3/8 in.
Ref. 803 585-C
OM-363 Page 31
A complete Parts List is available at www.MillerWelds.com
4-22. Connecting Input Power
1
8
=GND/PE Earth Ground
10
7
9
L1
L2
6
4
1
2
6
5
4
3
Tools Needed:
3/8 in.
Input9 2013−02 / 803 585-C
OM-363 Page 32
A complete Parts List is available at www.MillerWelds.com
4-22 Connecting Input Power (Continued)
Welding Power Source Input Power Connections
Disconnect Device Input Power Connections
2
7
Disconnect Device (switch shown in
OFF position)
8
Disconnect Device (Supply) Grounding
Terminal
!
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.
Route conductors (cord) through strain relief
and tighten screws.
!
3
Machine Grounding Terminal
Make input power connections to the
welding power source first.
4
Green Or Green/Yellow Grounding
Conductor
!
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
See rating label on unit and check input voltage available at site.
1
Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 4-20. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
Strain Relief
Connect green or green/yellow grounding
conductor to welding power source grounding
terminal first.
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
9
Disconnect Device Line Terminals
Connect input conductors L1 and L2 to
disconnect device line terminals.
5
Welding Power Source Line Terminals
10 Overcurrent Protection
6
Input Conductors L1 And L2
Select type and size of overcurrent protection
using Section 4-20 (fused disconnect switch
shown).
Connect input conductors L1 and L2 to welding power source line terminals.
Close and secure access door on welding
power source.
Close and secure door on line disconnect device. Follow established lockout/tagout procedures to put unit in service.
Input9 2013−02
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-363 Page 33
A complete Parts List is available at www.MillerWelds.com
SECTION 5 − OPERATION
5-1. Controls (350 LX Nameplates Shown)
11
1
2
3
4
5
6
12
10
9
7
Top row of lights in upper left corner are
On for SMAW. Bottom row are On for
GTAW.
Green on nameplate indicates a TIG function,
Gray indicates a Stick function.
1
Process Control
See Section 5-3.
2
Amperage Control
See Section 5-4.
3 Output Control
See Section 5-5.
4 Start Mode Control
See Section 5-9.
5
Voltmeter And Ammeter
Voltmeter displays average voltage (to the
nearest 0.1 V) at the weld output terminals.
Use meter to preset amperage. Meter displays average weld amperage output of unit
to nearest ampere when welding.
Meters are self-calibrating. No adjustment
OM-363 Page 34
8
available.
6 Amperage Adjustment
Control
Use control to adjust amperage, and preset
amperage on ammeter. This control may be
adjusted while welding.
For remote amperage control, front panel
control setting is the maximum amperage
available. For example: If front panel control
is set to 200 amps, the range of the remote
amperage control is 3 to 200 amps for 250 DX
models, and 3 to 200 amps for 350 LX
models.
For pulse welding, use Amperage Adjust
control to select from 3-300 amps of peak amperage for 250 DX models, or 3−400 amps of
peak amperage for 350 LX models (see Section 5-12).
For spot welding, use Amperage Adjust
control to select from 3-310 amps for 250 DX
models, or 3−400 amps for 350 LX models
(see Section 5-16).
7 Output Selector Switch
See Section 5-2.
8 Power Switch
Use switch to turn unit Off and On.
9 Postflow Time Control
Use control to set length of time (0−50 seconds) gas flows after welding stops. It is important to set enough time to allow gas to flow
until after the tungsten and weld puddle has
cooled down.
Application:
Postflow is required to cool the tungsten and
weld, and to prevent contamination of tungsten and weld. Increase postflow time if tungsten or weld are dark in appearance (approximately 1 second per 10 ampere of welding
current).
10 Balance/DIG Control
See Section 5-10.
11 Pulser Controls (Optional on 250 DX
model)
See Section 5-12.
12 Sequence Controls (Optional)
See Section 5-13.
217 264-D / 213 106-A
A complete Parts List is available at www.MillerWelds.com
5-2. Output Selector Switch
1
Output Selector Switch
!
Do not use AC output in
damp areas, if movement is
confined, or if there is danger of falling. Use AC output
ONLY if required for the
welding process, and then
use a remote control.
!
Do not change position of
switch while welding or
while under load.
1
Use switch to select (DCEN) Direct
Current Electrode Negative, AC, or
(DCEP) Direct Current Electrode
Positive output.
Changing position of Output Selector switch may change Process
control, Current control, and Start
Mode control, and may require
changing Output control settings to
properly function with latest Output
Selector switch setting.
5-3. Process Control
1
Process Control
Use control to select Stick or TIG
process.
2
2
STICK Process
For Stick process, press button to
toggle LED to Stick position.
3
TIG Process
For TIG process, press button to
toggle LED to TIG position.
Lit LED indicates selected mode.
When Output Selector switch position changes, LED may change
position, based upon last selection.
3
1
Ref. 217 264-D / Ref. 215 460-A
5-4. Amperage Control
1
Amperage Control
Use control to select front panel or
remote amperage control.
2
2
Front Panel Position
For front panel amperage control,
press button to toggle LED to Panel
position.
3
Remote Amperage Position
For remote amperage control,
press button to toggle LED to Remote position (see Section 4-10).
3
1
Lit LED indicates selected mode.
When Output Selector switch position changes, LED may change
position, based upon last selection.
OM-363 Page 35
A complete Parts List is available at www.MillerWelds.com
5-5. Output Control
Remote (Standard)Torch Trigger Operation
2
1
Current (A)
Remote (Standard)Torch Trigger Operation
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Foot Or Finger
Remote Control
Release For
Maintained Switch
1
Output Control
2
!
Weld output terminals are energized when power is On, and Output On LED is lit.
For remote output control, press button to
toggle LED to Remote position (see Section 4-10).
Use control to select front panel, trigger
hold, or remote output control.
Lit LED indicates selected mode.
For weld output, press button to toggle LED
to On position.
OM-363 Page 36
Remote Trigger (Standard) Operation
Release Foot Or
Finger Remote
Control
If On/Off only type trigger is used, it must be
a maintained switch. All functions become
active.
Torch trigger operation is as shown.
Application: Use Remote Trigger when
the operator desires to use a foot pedal or
finger amperage control.
Initial weld amperage and final amperage
is controlled by the remote device, not by
the welding power source.
When Output Selector switch (see Section
5-2) position changes, Output control LED
will always switch to Remote.
A complete Parts List is available at www.MillerWelds.com
Trigger Hold (2T)
3
Current (A)
2T Torch Trigger Operation
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release Trigger
In Less Than 3/4 Sec.
Push & Release Trigger
In Less Than 3/4 Sec.
If torch trigger is held more than 3 seconds, operation reverts to Remote Trigger (Standard) mode (see previous page).
If arc is broken and trigger is depressed, HLP-10 will be displayed (see Section 7-1).
3 Trigger Hold
For trigger hold operation, press button to
toggle LED to Trigger Hold position.
Torch trigger operation is as shown.
When a foot or finger remote control is
connected to the welding power source,
only trigger input is functional, as amperage is controlled by the welding power
source.
Application: Trigger Hold (2T) can help
to reduce operator fatigue when long extended welds are made.
OM-363 Page 37
A complete Parts List is available at www.MillerWelds.com
5-6. 4T, 4T Momentary, And Mini Logic Trigger Operation (Requires Optional Sequence
Controls)
4T Torch Trigger Operation
If unit is equipped with optional Sequence
Controls (see Section 5-13), 4T trigger
method is available.
lows the operator to toggle between weld
current and final current without breaking
the arc.
4T torch trigger operation is as shown.
When a remote switch is connected to the
welding power source, only trigger input is
functional. Amperage is controlled by the
welding power source.
While in 4T mode, there is a feature available during the main weld sequence that al-
Application:
Use 4T trigger method when the functions
of a remote current control are desired, but
only a remote on/off control is available.
Select 4T trigger method according to Section 5-7.
Current (A)
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Hold
Trigger
Release
Trigger
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger
Release
Trigger
4T Momentary Torch Trigger Operation
If unit is equipped with optional Sequence
Controls (see Section 5-13), 4T Momentary trigger method is available.
4T Momentary torch trigger operation is as
shown.
While in 4T Momentary mode, once the operator toggles out of weld current and begins final slope, toggling again will break
the arc and go to postflow.
When a remote switch is connected to the
welding power source, only trigger input is
functional. Amperage is controlled by the
welding power source.
Application:
Use 4T Momentary trigger method when
the functions of a remote current control are
desired, but only a remote on/off control is
available.
Select 4T Momentary trigger method according to Section 5-7.
Current (A)
Weld Amps
Final Slope
Initial Amps
Final Amps
Postflow
Preflow
Push & Release
Trigger
OM-363 Page 38
Push & Release
Trigger
Push & Release
Trigger
Push & Release
Trigger
A complete Parts List is available at www.MillerWelds.com
Mini Logic Operation
If unit is equipped with optional Sequence
Controls (see Section 5-13), Mini Logic operation is available.
Torch trigger operation is as shown.
During Mini Logic welding operation, the
weld amperage can be manually changed
from the initial amps level to the main weld
amps level by pressing and releasing the
torch trigger in less than 3/4 seconds.
When a remote switch is connected to the
welding power source, only trigger input is
functional. Amperage is controlled by the
welding power source.
Application: This ability to change amperage levels without either initial slope or final
slope, gives the operator the opportunity to
adjust filler metal without breaking the arc.
Select Mini Logic according to Section 5-7.
Weld Amps
Final Slope
Initial Amps
Initial Amps
Final Slope
Rate
Preflow
Push & Hold
Trigger
Push & Hold
Trigger For More
Than 3/4 Sec.
Release Trigger
Push & Release
Trigger In Less
Than 3/4 Sec.
Postflow
Push & Release
Trigger In Less
Than 3/4 Sec.
Push & Hold
Trigger For More
Than 3/4 Sec.
Push & Release
Trigger In Less
Than 3/4 Sec.
OM-363 Page 39
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5-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control
1
2
2
Output Control
Power Switch
To reconfigure Trigger Hold, turn Off
power, push and hold Output control
button and turn On power switch.
Hold button for approximately 7 seconds (or until software version number _ _ _ _ _ _-_clears, and meters
display [SEL] [H−2].
Press Output control button to
change functions. Active function will
be displayed on amperage (bottom)
meter.
Front Panel
3
Meter Displays
Meter displays for the different functions will be as shown.
1
Press torch trigger or turn power Off
to save setting.
Proceed to Section 5-6 for 4T Operation.
SEL
H−2
SEL
SEL
= 4T Momentary
H-4E
H−4
Proceed to Section 5-6 for 4T Momentary operation.
These features are only available
when optional Sequencer is
installed.
SEL
= Mini Logic (See Section 5-6)
= 4T (See Section 5-6)
(See Section 5-6)
Proceed to Section 5-6 for Mini Logic
operation.
H4L
3
OM-363 Page 40
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5-8. Selecting TIG Starting Characteristics Using Syncro-Startt Technology
1
4
E−
−2−
2
3
Use this function to select desired TIG starting characteristics.
1 Start Mode
2 Power Switch
3 Output Selector Switch
4 Meters
To select or change TIG starting characteristics, proceed as follows: turn Off power.
Place Output Selector switch in desired
position (each position, DCEN, AC, or
DCEP has three applicable start characteristics options). Push and hold Start Mode
button and turn On power. Hold button for
approximately 7 seconds (or until software
version number_ _ _ _ _ _-_ clears meters).
Press torch trigger or turn Off power to save
setting.
The TIG LED and all four Start LEDs will
light, and the meters will display [E−] [−2−],
[AC] [−2−], or [EP] [−2-], depending on position of Polarity switch.
Select 1 (light/soft start) − when welding at
low amperages on thin gauge material.
Press Start Mode button again to step
through the three start characteristics
choices. Amperage (bottom) meter displays active choice 1= light start, 2=medium/
normal start, 3=high/hot start.
Application:
Select 2 (medium/normal start) − factory
default setting used for most welding applications.
Select 3 (high/hot start) − when welding at
high amperages on thick materials with a
large diameter tungsten.
OM-363 Page 41
A complete Parts List is available at www.MillerWelds.com
5-9. Start Mode
2
1
3
4
Lift-Arc Start Method
“Touch”
1−2
Seconds
Do NOT Strike Like A Match!
1
2
Start Mode
OFF Position
For SMAW welding, press button to toggle
LED to Off position.
For GTAW welding, use control to select
Off for no HF, Lift-Arc, HF for arc starting
only, or continuous HF.
Application:
When Off is selected, use the scratch
method to start an arc for both the SMAW
and GTAW processes.
When Lift-Arc is selected, start arc as
follows:
3
TIG Electrode
4
Workpiece
Touch tungsten electrode to workpiece at
weld start point, enable output with torch
trigger, foot control, or hand control. Hold
electrode to workpiece for 1-2 secOM-363 Page 42
onds, and slowly lift electrode. An arc will
form when electrode is lifted.
turns off when arc is started, and turns on
whenever arc is broken to help restart arc.
Shielding gas begins to flow when electrode touches work piece.
Application:
Normal open-circuit voltage is not present
before tungsten electrode touches workpiece, only a low sensing voltage is present between electrode and workpiece.
The solid state output contactor does not
energize until after electrode is touching
workpiece. This allows electrode to touch
workpiece without overheating, sticking,
or getting contaminated.
Application:
Lift-Arc is used for the DCEN GTAW process when HF Start method is not permitted, or to replace the scratch method.
HF Start is used when the DCEN GTAW
process is required.
When HF Continuous is selected, start
arc as follows:
High frequency turns on when output is
energized and remains on for duration of
weld.
Application:
HF Continuous is used when the AC
GTAW process is required.
Lit LED indicates selected mode.
When HF Start is selected, start arc as
follows:
When Output Selector switch position
changes, LED may change position,
based upon last selection.
High frequency turns on to help start arc
when output is enabled. High frequency
Some start methods may not be available
for all processes.
A complete Parts List is available at www.MillerWelds.com
5-10. Balance/DIG Control
1
Balance/DIG Control
Balance Control (AC GTAW):
AC Balance controls the cleaning
action. Increasing the balance setting reduces the oxide cleaning.
Adjusting balance: Set the balance
level in the AC TIG zone. Make a
test weld. If floating black specs appear in the welding puddle, balance
is set too high. Turn balance down
and repeat until puddle is clear.
1
DIG Control (AC And DC SMAW):
When set at 0, short-circuit amperage at low arc voltage is the same
as normal welding amperage.
When setting is increased, shortcircuit amperage at low arc voltage
increases. Set control at 2 and adjust as necessary. Joint configuration, set-up, and process variables
may affect setting.
Application:
Balance Control Examples
Output Waveforms
Setting
Balanced
3
Arc
Control helps arc starting or making
vertical, or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking
while welding.
50% Electrode
Positive
50% Electrode
Negative
Min Cleaning
10
Max Cleaning
0
32% Electrode
Positive
68% Electrode
Negative
55% Electrode
Positive
45% Electrode
Negative
Ref. S-0795-A
OM-363 Page 43
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5-11. Preflow Time Control
3
00.4
4
1
SEL
2
Use control to set length of time (0.2, 0.4,
0.6, 0.8, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5,
5.0 seconds) gas flows before welding
starts.
1 Process Control
2 Power Switch
3 Meters
To change preflow time, proceed as follows:
OM-363 Page 44
Turn power off. Push and hold Process Control button and turn On power. Hold button for
approximately 7 seconds (or until software
version number_ _ _ _ _ _-_ clears meters).
4 TIG LED
time, press and release Process Control
button until desired time is displayed on meters.
The TIG LED will light and the meters will display [o.4] [SEL]. The factory preflow default
setting is 0.4 seconds. To change preflow
Preflow is used to purge the immediate weld
area of atmosphere. Preflow also aids in
consistent arc starting.
Application:
A complete Parts List is available at www.MillerWelds.com
5-12. Pulse Controls (Standard On 350 LX Models, Optional On 250 DX Models)
1
On/Off Control
Use control to turn pulse function
On and Off.
2
Pulser ON LED
LED is lit when pulser function is
enabled.
3
2
4
3
1
5
Background Amps
Use Background Amps control to
set the low pulse of the weld amperage, which cools the weld puddle
and affects overall heat input.
Background Amps is set as a percentage of peak amperage.
4
Pulse Frequency
Ranges from 0.25−10.0 pps
(pulses per second). Control is
used to determine appearance of
weld bead.
5
Peak Time
A range of 5−95% of each pulse
cycle can be spent at the peak amperage level.
6
Peak amperage (3-310 amps for
250 DX models, and 3−400 amps
for 350 LX models), is set with the
Amperage Adjustment control (see
Section 5-1). Peak amperage is the
highest welding amperage allowed
to occur in the pulse cycle. Weld
penetration varies directly with
peak amperage.
6
Percent (%) Peak
Time Control Setting
Pulsed Output Waveforms
PPS
(50%)
Bkg Amp
Balanced
Peak Amp
More Time
At Peak
Amperage
More Time At
Background
Amperage
(80%)
Pulsed Output Waveforms
Example shows affect changing
the Peak Time control has on the
pulsed output waveform.
Application:
Pulsing refers to the alternating
raising and lowering of the weld
output at a specific rate. The raised
portions of the weld output are controlled in width, height, and frequency, forming pulses of weld output.
These pulses and the lower amperage level between them (called the
background amperage) alternately
heat and cool the molten weld
puddle. The combined effect gives
the operator better control of penetration, bead width, crowning, undercutting, and heat input. Controls
can be adjusted while welding.
Pulsing can also be used for filler
material addition technique training.
(20%)
OM-363 Page 45
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5-13. Sequence Controls (Optional)
1
Initial Time Control
See Section 5-14.
2
1
Initial Amperage Control
See Section 5-14.
5
3
3
Final Slope Control
See Section 5-15.
4
Final Amperage Control
See Section 5-15.
5
Spot Time Control
See Section 5-16.
4
2
5-14. Initial Time Control And Initial Amperage Control
1
Initial Time Control
Indicator light is on when Initial Time
control function is active.
Initial Sequence control function is
inactive when Spot Time function is
active.
1
Use control to select 0−15 seconds
of start time.
2
Initial Amperage Control
Indicator Light is on when Initial Sequence control function is active.
Initial Amperage control function is
inactive when Spot Time function is
active.
Use control to select a starting amperage (3−400 amps) that is different
from the weld amperage. Initial Amperage can be used with or without a
remote control (Initial Amperage and
Initial Time control settings will override a remote control device).
2
Application:
Initial Amperage can be used while
GTAW welding to assist in preheating cold material prior to depositing
filler material, or to ensure a soft
start. Initial Amperage can also be
used for SMAW to ensure a more
consistent arc strike.
Function is enabled, when LED is lit.
OM-363 Page 46
A complete Parts List is available at www.MillerWelds.com
5-15. Final Slope Control And Final Amperage Control
1
Final Slope Control
Indicator light is on when Final Slope
control function is active.
Final Slope control function is inactive
when Spot Time function is active.
Use control to reduce amperage over
a set period of time (0−15 seconds) at
the end of the weld cycle when NOT
using a remote current control.
1
2
Final Amperage Control
Indicator light is on when Final Amperage control function is active.
Final Amperage control function is inactive when Spot Time function is active (see Section 5-16).
Final amperage is the amperage to
which weld amperage has sloped
down to (0−100% of amperage set on
Amperage Adjust control).
Application:
Final Slope should be used while
GTAW welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
2
This applies if the operator is using an
on/off only type control to start and
stop the welding process.
Do not use this function with a foot or
finger amperage control.
Function is enabled, when LED is lit.
5-16. Spot Time Control
1
1
Spot Time Control
Indicator light is on when Spot Time function is active. When Spot Time function is
active, Initial Time, Initial Amperage, Final
Slope, and Final Amperage functions are
inactive (see Section 5-13).
Used with the (GTAW) TIG Spot process,
generally with a direct current electrode
negative (DCEN) set-up.
Use control to select 0−15 seconds of spot
time.
Use Amperage Adjust control (see Section
5-1) to set amperage.
Application:
TIG spot welding is used for joining thinner
materials that are in close contact with the
fusion method. A good example would be
joining coil ends.
Function is enabled, when LED is lit.
OM-363 Page 47
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5-17. Timer/Cycle Counter
1 2 3
1
2
3
4 5 6
1 2 3
4
4 5 6
1 Amperage Control
2 Output Control (Contactor)
To read timer/cycle counter, hold Amperage and Output (contactor) buttons while
turning on power. When machine first
powers up, the displays will show the
OM-363 Page 48
software number and revision for the first
seven seconds. It will then show arc time
and cycle count.
3 Timer Display
The hours and minutes are displayed on
the volt and amp meters for the first five
seconds, and are read as 1, 234 hours
and 56 minutes.
4 Cycle Display
The cycles are displayed on the volt and
amp meters for the next five seconds,
and are read as 123, 456 cycles.
A complete Parts List is available at www.MillerWelds.com
5-18. Resetting Unit To Factory Default Settings (All Models)
1
2
3
4
5
Process Control
Amperage Control
Output Control
Start Control
Power Switch
To reset all welding power source functions to
original factory settings, turn power off. Push
and hold the Process, Amperage, Output, and
Start controls and turn On power. Hold switch
pads for approximately 7 seconds (or until
software version number _ _ _ _ _ _-_clears
meters).
1
2
3
4
00.4
SEL
5
For additional welding information and resources, visit: www.MillerWelds.com/resources/improving−your skills
OM-363 Page 49
A complete Parts List is available at www.MillerWelds.com
SECTION 6 − MAINTENANCE
6-1. Routine Welding Power Source Maintenance
!
Disconnect power before maintaining.
Maintain more often during severe conditions.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Δ = Repair
= Replace
Every
3
Months
Labels
Weld Terminals
Gas Hoses
Every
3
Months
Δ
Cables And Cords
Every
6
Months
0.008 in.
(0.203 mm)
Durning heavy service, clean monthly.
* Adjust or clean spark gap
6-2. Supplementary Protector CB1
!
Turn off power before resetting breaker.
1
Supplementary Protector CB1
If CB1 opens, high frequency and
output to the 115 volts AC duplex
receptacle stop. Press button to reset CB1.
1
Ref. 803 588-B
OM-363 Page 50
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6-3. Adjusting Spark Gaps
!
Remove right side panel..
2
1
Turn Off welding power
source and disconnect and
lockout/tagout input power
before adjusting spark gaps.
1
Tungsten End Of Point
Replace point if tungsten end disappears; do not clean or dress
tungsten.
2
4
Spark Gap
Normal spark gap is 0.008 in (0.203
mm).
If adjustment is needed, proceed as
follows:
3
3
Adjustment Screws
Loosen screws. Place gauge of
proper thickness in spark gap.
4
Pressure Point
Apply slight pressure at point until
gauge is held firmly in gap. Tighten
screws. Adjust other gap.
Tools Needed:
Reinstall right side panel.
0.008 in. (0.203 mm)
5/32 in.
3/8 in.
803 592-C
6-4. Routine Maintenance For Optional Cooler
!
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
Every
Month
Δ = Repair
Disconnect power
before maintaining.
= Replace
NOTICE − Clean coolant strainer. Severe conditions may require more frequent cleaning
(continuous use, high/low temperatures, dirty
environment, etc.). Failure to properly
clean coolant strainer voids pump warranty.
Coolant Strainer
Heat Exchanger Fins
Every
Six
Months
Unreadable Labels
Cracked Hoses
Change Coolant If Using Water (See
Section 6-5)
Every
Twelve
Months
Change Coolant (If Using Miller Coolant) (See Section 6-5)
OM-363 Page 51
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6-5. Coolant Maintenance
!
Disconnect power
before maintaining.
1
Coolant Filter
Unscrew housing to clean filter.
Changing coolant: Drain coolant by
tipping unit forward. Fill with clean
water and run for 10 minutes. Drain
and refill.
NOTICE − If replacing hoses, use
hoses compatible with ethylene
glycol, such as Buna-n, Neoprene,
or Hypalon. Oxy-acetylene hoses
are not compatible with any product
containing ethylene glycol.
805 516-A
1
GTAW Or Where
HF* Is Used
Application
3-1/2
Gal
Low Conductivity Coolant
No. 043 810**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**Coolant 043 810, a 50/50 solution, protect to -37° F (-38°C) and resist algae growth.
NOTICE − Use of any coolant other than those listed in the table voids the warranty
on any parts that come in contact with the coolant (pump, radiator, etc.)
OM-363 Page 52
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SECTION 7 − TROUBLESHOOTING
7-1. Voltmeter/Ammeter Help Displays
0
1
2
3
4
5
V
V
V
V
V
V
HLP
HLP
HLP
HLP
HLP
HLP
A
A
A
A
A
A
−−1
−−2
−−3
−−4
−−5
−−0
6
7
9
8
V
V
V
V
HLP
HLP
HLP
HLP
A
A
A
A
−−9
−10
−11
−12
All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.
0
Help 0 Display
Indicates a short in the thermal protection circuitry located on the
transformer/stabilizer of the unit.
1
Help1 Display
An SCR overcurrent or undercurrent condition has occurred.
Turn power off and back on to correct condition.
2
Help 2 Display
Indicates an open in the thermal protection circuitry located on
the transformer/stabilizer of the unit.
3
Help 3 Display
Indicates the transformer/stabilizer of the unit has overheated.
The unit has shut down to allow the fan to cool it (see Section
4-7). Operation will continue when the unit has cooled.
4 Help 4 Display
Indicates an open in the thermal protection circuitry located on
the rectifier assembly of the unit.
5 Help 5 Display
Rectifier assembly has overheated. The unit has shut down to
allow the fan to cool unit (see Section 4-7). Operation will continue when the unit has cooled.
6 Help 9 Display
Indicates a short in the thermal protection circuitry located on the
rectifier assembly of the unit.
7 Help 10 Display
Indicates Remote Output control is activated. Release Remote
Output control to clear help message.
8 Help 11 Display
Output Selector switch is not in correct position (see Section
5-2).
9 Help 12 Display
Indicates a non-allowable set-up of the front panel.
OM-363 Page 53
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7-2. Troubleshooting The Welding Power Source
NOTICE − The remedies listed below are recommendations only. If these remedies do
not fix the trouble with your unit, have a Factory Authorized Service Agent check unit.
There are no user serviceable parts inside unit.
Refer to Section 7-1 for any Help (HLP) message displayed on voltmeter/ammeter.
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 4-22).
Check and replace line fuse(s), if necessary (see Section 4-22).
Check for proper input power connections (see Section 4-22).
Check for proper jumper link position (see Section 4-21).
No weld output; unit on.
If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 5-1).
Check, repair, or replace remote control.
Have Factory Authorized Service Agent check unit.
Unit provides only maximum or
minimum weld output.
Make sure Amperage control is in proper position (see Section 5-1).
Have Factory Authorized Service Agent check unit.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 4-9).
Clean and tighten all weld connections.
Check position of Output Selector control (see Section Figure 5-1).
If using remote control, check position of Amperage Adjustment control (see Section 5-1).
No control of weld output.
If using remote control, place Output control in Remote 14 position, and make sure remote control is
connected to Remote 14 receptacle. If remote is not being used, place Output control in On position
(see Section 5-1).
Make sure Amperage control is in proper position (see Section 5-1).
No output from cooler receptacle RC2
and no high frequency.
Reset circuit breaker CB1 (see Section 6-2).
Lack of high frequency; difficulty in
starting GTAW arc.
Reset circuit breaker CB1 (see Section 6-2).
Select proper size tungsten (see Section 11).
Be sure torch cable is not close to any grounded metal.
Check cables and torch for cracked insulation or bad connections. Repair or replace.
Check spark gaps (see Section 6-3).
Wandering arc − poor control of
direction of arc.
Reduce gas flow rate.
Select proper size tungsten (see Section 11).
Properly prepare tungsten (see Section 11).
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Properly prepare tungsten.
Check for water in torch, and repair torch if necessary.
Fan not operating.
OM-363 Page 54
Unit equipped with Fan-On-Demand. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.
A complete Parts List is available at www.MillerWelds.com
7-3. Troubleshooting The Optional Cooler
Trouble
Remedy
Coolant system does not work.
Be sure input power cord is plugged in to energized receptacle.
Check line fuses or circuit breaker, and replace or reset if necessary.
Motor overheated. Unit starts running when motor has cooled.
Have Factory Authorized Service Agent check motor.
Decreased or no coolant flow.
Add coolant.
Check for clogged hoses or coolant filter.
Disconnect pump, and check for sheared coupling. Replace coupling if necessary.
SECTION 8 − PARTS LIST
8-1. Recommended Spare Parts
Dia.
Mkgs.
Part
No.
Quantity
Model
250 350
Recommended Spare Parts
DX
LX
. . . . . . . . . . . . . . . . 221 736 . . . . POINTS, SPARK GAP (DUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . 221 737 . . . . POINTS, SPARK GAP (SINGLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 2
. . . . . . . . . . . . . . . . 239 494 . . . . Screen, Filter Lp Cyl 100x100x0.0045 SST (For Optional Cooler) . . . . . 1 . . . 1
Description
OM-363 Page 55
SECTION 9 − ELECTRICAL DIAGRAM
Figure 9-1. Circuit Diagram For 250 DX Models
OM-363 Page 56
231 394-C
Figure 9-2. Circuit Diagram For 350 LX Models
231 395-B
OM-363 Page 57
225 650-A
Figure 9-3. Circuit Diagram For Optional Cooler
OM-363 Page 58
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-363 Page 59
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-363 Page 60
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
gtaw_Phase_2011−06
!
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
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.040” (1 mm)
25-85
20-80
1/16” (1.6 mm)
50-160
50-150
3/32” (2.4 mm)
130-250
135-235
1/8” (3.2 mm)
250-400
225-360
Pure Tungsten
.040” (1 mm)
Pure Tungsten Not Recommended
10-60
1/16” (1.6 mm)
For DCEN − Argon
50-100
3/32” (2.4 mm)
100-160
1/8” (3.2 mm)
150-210
♦Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
11-2. Preparing Tungsten Electrode For Welding With Phase Control 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.
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding
2-1/2 Times
Electrode Diameter
Radial Grinding
Causes Wandering Arc
1
3
2
1
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
Wrong Tungsten Preparation
Ideal Tungsten Preparation − Stable Arc
3
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
B. Preparing Tungsten For AC Welding
1
Tungsten Electrode
A pure tungsten is recommended..
1 − 1-1/2 Times
Electrode Diameter
1
2
2
Balled End
Ball end of tungsten by applying AC amperage recommended for a given electrode
diameter (see Section 11-1). Let ball on end
of the tungsten take its own shape.
OM-363 Page 61
Notes
For additional welding information and resources, visit:
www.MillerWelds.com/resources/improving-your skills
Effective January 1, 2013
(Equipment with a serial number preface of MD 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
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
* MIG Guns and Subarc (SAW) Guns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed.
* Replacement Parts (No labor)
* Roughneck Guns
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
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 one year 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
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Oxy-Fuel Cutting Torches (No Labor)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith Series 30 Flowgauge, Flowmeter, and Pressure
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Filtair 400 and Industrial Collector
Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* 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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* Load Banks
* Motor Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
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
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2013-01
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)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2013 Miller Electric Mfg. Co.
2013−01
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