Miller SYNCROWAVE 250 DX W/INTEGRATED COOLER Owner’s Manual

OM-362
212 546A
June 2004
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
R
Syncrowave 250 DX
And
R
Syncrowave 250 DX
w/Integrated Cooler
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
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. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Torch/Cable Holder Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Cooler Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Welding Power Source Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Cooler Connections And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. TIG Connections With A Water-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. TIG Connections With A Two-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. TIG Connections With A One-Piece Air-Cooled Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Front Panel Display For TIG HF Impulse DCEN (Direct Current Electrode Negative) . . . . . . . . . . . . .
4-15. Front Panel Display For TIG AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Stick Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Front Panel Display For Stick DCEP (Direct Current Electrode Positive) . . . . . . . . . . . . . . . . . . . . . . .
4-18. Front Panel Display For Stick AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Output Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. 4T, 4T Momentary, And Mini Logoic Trigger Operation (Requires Optional Sequence Controls) . . . . .
5-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Selecting TIG Starting Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Balance/DIG Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Preflow Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Pulse Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
4
5
5
5
7
8
8
9
9
9
10
11
11
12
12
12
14
15
16
16
17
18
19
19
20
21
22
23
24
25
26
27
28
29
29
31
31
31
32
34
36
38
40
41
42
44
TABLE OF CONTENTS
5-13. Sequence Controls (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Initial Time Control And Initial Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Final Slope Control And Final Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Spot Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Timer/Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18. Resetting Unit To Factory Default Settings (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Welding Power Source Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Routine Cooler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Adjusting Spark Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Troubleshooting The Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Troubleshooting The Welding Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING . .
10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . .
10-2. Preparing Tungsten Electrode For Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
45
46
47
47
48
49
50
50
50
51
51
52
52
53
54
55
56
56
56
57
58
58
58
60
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-362 Page 1
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-362 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-362 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-362 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
OM-362 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LE SOUDAGE peut causer un incendie ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer 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.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer 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 agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-362 Page 6
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
D
D
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte−bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre
l’appareil en service.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-362 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-362 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
Warning! Watch Out! There are possible
hazards as shown by the symbols.
1
Electric shock from welding electrode
or wiring can kill.
2
2.1
2.2
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
2.3
3
1.2 Protect yourself from electric shock
by insulating yourself from work and
ground.
3.1
3.2
1.3 Disconnect input plug or power before
working on machine.
1
1.1
2
2.1
3
3.1
1.2
Breathing welding fumes can be
hazardous to your health.
Keep your head out of the fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove fumes.
Welding sparks can cause explosion
or fire.
Keep flammables away from welding.
Do not weld near flammables.
Welding sparks can cause fires. Have
a fire extinguisher nearby, and have a
watchperson ready to use it.
4
1.3
2.2
2.3
3.2
3.3 Do not weld on drums or any closed
containers.
4
Arc rays can burn eyes and injure
skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
5
Become trained and read the
instructions before working on the
machine or welding.
6
Do not remove or paint over (cover)
the label.
4.1
5
3.3
6
197 310-A
3-2. Torch/Cable Holder Label
1
3
1
2
3
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Do not operate unit or reach
inside when torch/cable
holder is removed.
Do not exceed 25 lb (12.4 kg)
maximum load on gun/cable
holder or holder may break.
2
OM-362 Page 9
3-3. Symbols And Definitions
NOTE
A
V
Some symbols are found only on CE products.
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
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
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-Arct
Trigger Hold
Pulser On-Off
Pulse Frequency
S
OM-362 Page 10
4T
4 Step Trigger Operation Sequence
Input
SECTION 4 − INSTALLATION
4-1. Selecting A Location
Y Falling
Injury.
S
Movement
S
1
S
OR
2
1
2
Unit
Can
Cause
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.
Lifting Eye
Lifting Forks
Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
3
4
Serial Number/Patent Label
Rating Label
Use rating label to determine input
power needs.
5
Line Disconnect Device
Locate unit near correct input power supply.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Y Be careful when placing or
moving unit over uneven
surfaces.
3
Location And Airflow
5
SERIAL NO.
STOCK NO.
XXXXXXX3
XXXXXXXXXXXXXX4
LR5071

C
US
PROTECTED B Y ONE OR MORE OF THE
FOLLOWING US. PATENTS:
XXXXX05
XXXXX06
XXXXX07
XXXXX09
XXXXX10
XXXXX11
XXXXX15
XXXXX21
XXXXX24
XXXXX25
XXXXX26
XXXXX32
XXXXX42
XXXXX47
XXXXX48
EVIDENCE OF LABEL T AMPERING VOIDS WARRANTY
1
4
18 in (460 mm)
18 in (460 mm)
Ref. 117 264-C / 803 584-A / 216 202-D / 208 998
OM-362 Page 11
4-2. Dimensions And Weights
Dimensions
A
D
C
C
B
G
Front
E
F
H
803 616-A
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 (565 mm)
G
1-1/8 in (29 mm)
H
1/2 in (13 mm) Dia
Weight
400 lbs (181 kg)
4-3. Cooler Specifications
Cooler Specifications
Cooler Tank Capacity
3 gallons (11.4 L)
Coolant Flow Rate 1 liter per minute (1.1 quart)
Use With Torches Rated Up To 400 Amperes
4-4. Welding Power Source Specifications
Amperes Input at AC Balanced Rated
Load Output, 60 Hz, Single-Phase
Rated
Welding Output
PFC**
200V
230V
460V
575V
KVA
KW
NEMA Class I (40) −
200 Amperes, 28
Volts AC, 60% Duty
Cycle
No
PFC
88
77
38
31
17.6
8.6
*3.3
*2.8
*1.5
*1.1
*.59
*.29
NEMA Class I (40) −
200 Amperes, 28
Volts AC, 60% Duty
Cycle
With
PFC
60
52
26
21
12.06
8.11
*55.3
*49.5
*24.5
*19.6
*11.2
*.39
NEMA Class II (40) −
250 Amperes, 30
Volts AC, 40% Duty
Cycle
No
PFC
110
96
48
38
21.98
11.76
*3.3
*2.8
*1.5
*1.1
*.59
*.29
NEMA Class II (40) −
250 Amperes, 30
Volts AC, 40% Duty
Cycle
With
PFC
82
71
35
28
16.32
11.81
*55.3
*49.5
*24.5
*19.6
*11.2
*1.93
*While idling
**Power Factor Correction
OM-362 Page 12
Amperage
Range
Max
OCV
3 − 310A
80V
3 − 310A
80V
3 − 310A
80V
3 − 310A
80V
4-4.
Welding Power Source Specifications(continued)
Amperes Input at AC Balanced Rated
Load Output, 50/60 Hz, Single-Phase
Rated
Welding Output
PFC**
220V
400V
NEMA Class I (40) −
200 Amperes, 28
Volts AC, 60% Duty
Cycle
No
PFC
82
45
*3.0
*1.6
NEMA Class I (40) −
200 Amperes, 28
Volts AC, 60% Duty
Cycle
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
NEMA Class II (40) −
250 Amperes, 30
Volts AC, 40% Duty
Cycle
With
PFC
81
44
*45.9
*25.1
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
Amperage
Range
Max
OCV
3 − 310A
80V
3 − 310A
80V
3 − 310A
80V
3 − 310A
80V
Amperage
Range
Max
OCV
3 − 310A
80V
3 − 310A
80V
3 − 310A
80V
3 − 310A
80V
*While idling
**Power Factor Correction
Amperes Input at AC Balanced Rated
Load Output, 50 Hz, Single-Phase
Rated
Welding Output
PFC**
200V
230V
460V
575V
KVA
KW
NEMA Class I (40) −
175 Amperes, 27
Volts AC, 60% Duty
Cycle
No
PFC
80
69
35
28
15.9
7.4
*3.3
*2.8
*1.5
*1.1
*.59
*.29
NEMA Class I (40) −
175 Amperes, 27
Volts AC, 60% Duty
Cycle
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
NEMA Class II (40) −
225 Amperes, 29
Volts AC, 40% Duty
Cycle
With
PFC
74
64
32
26
14.7
10.1
*55.3
*49.5
*24.5
*19.6
*11.2
*1.93
*While idling
**Power Factor Correction
OM-362 Page 13
4-5. 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.
Y 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 Welding
6 Minutes Resting
4 Minutes Resting
Overheating
A
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 / Ref. 116 198
OM-362 Page 14
4-6. Volt-Ampere Curves
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.
Non CE Models
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
100
150
200
250
300
350
400
450
AMPS
AMPS
194 385-A / 194 384-A
CE Models
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
10
0
0
0
50
100
150
200
250
AMPS
300
350
400
450
0
50
100
150
200
250
300
350
400
450
AMPS
205 631 / 205 632
OM-362 Page 15
4-7. Weld Output Terminals And Selecting Cable Sizes
Y ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Weld Output
Terminals
Y Turn off power before
connecting to weld output terminals.
Welding
Amperes
10 − 60%
Duty
Cycle
60 − 100%
Duty
Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
Y Do not use worn, damaged, undersized, or
poorly spliced cables.
Electrode
Work
Ref. 803 588-A
10 − 100% Duty Cycle
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere
*Select weld cable size for pulsing application at peak amperage value..
S-0007-D
4-8. Remote 14 Receptacle Information
Socket*
Y Turn off power before
connecting to receptacle.
A
Contactor control 24 volts dc.
B
Contact closure to A completes 24 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.
24 VOLTS DC
A
B
K
J
I
H
C L N
D M
G
E F
Ref. 803 588-A
*The remaining sockets are not used.
OM-362 Page 16
Socket Information
OUTPUT
CONTACTOR
A
A/V
F
Current feedback; +1 volt dc per 100 amperes.
AMPERAGE
VOLTAGE
H
Voltage feedback; +1 volt dc per 10 volts output.
GND
K
Chassis common.
4-9. Shielding Gas Connections And 115 Volts AC Duplex Receptacle
Y Turn Off power before connecting to receptacle.
4
1
Gas Valve In Connection
Located on rear of unit.
3
5
2
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 Receptacle
Receptacle is protected from overload by circuit breaker CB1 (see
Section 6-3).
2
Rear View
Front View
1
6
Ref. 803 588-A / Ref. 803 585-A / Ref. 157 858
OM-362 Page 17
4-10. Cooler Connections And Operation
Cooler Tank Capacity: 3 gallons (11.4 L)
Cooler Flow Rate: 1 liter per minute (1.1 qt)
Tools Needed:
Use With Torches Rated Up To 400 Amperes
5/8, 3/4, 1-1/8 in
Y Turn Off power before connecting to coolant fittings.
1
Coolant Tank Cap
Use table below to select proper
coolant. Remove cap and add coolant. Fill to capacity. Keep coolant
level full.
Connect torch as shown in Section
4-11.
Priming
Initial setup requires priming of the
coolant system before operation.
To prime the system, proceed as
follows:
2
Process Control Switch
For cooler operation, place Process Control switch in the GTAW
(TIG) position according to Section
5-3.
1
Press and HOLD the Process Control switch. After 2 seconds the voltmeter displays [CLR] to indicate system priming has initiated.
2
Continue to hold the Process Control switch until the amp meter displays [FLO] to indicate priming is
complete and adequate flow has
been detected (approx. 40 seconds).
Operation
Cooler will activate when a valid arc
is detected. A system pressure
switch will detect and monitor coolant flow. If flow is not detected within
5 seconds of welding, weld output
stops, and a Help Message Code is
displayed on the volt/amp meters
(see Section 7-1).
During normal operation cooler will
continue to operate for 40 seconds
after welding arc ends, or until the
coolant temperature is adequately
reduced.
Changing A Water-Cooled Torch
Y Turn Off power before making torch and coolant connections.
GTAW Or Where
HF* Is Used
Application
MILLER Low Conductivity
Coolant No. 043 810**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**MILLER coolants protect to -37° F (-38°C) and resist algae growth.
Y 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-362 Page 18
Connect new torch and follow priming procedure described above. To
avoid a Help Message Code, press
and hold Process Control switch for
approximately 20 seconds to ensure the torch is completely primed,
even if amp meter displays [FLO]
sooner.
4-11. TIG Connections With A Water-Cooled Torch
Y Turn Off power before making connections.
1
Gas-In Connection
Connect gas hose from gas supply to gasin connector.
2
6
7
8
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 dispay, see Section 4-14. For TIG AC
welding, place switch in AC position. For
TIG AC front panel control dispay, see Section 4-15.
2
3
3
Electrode Weld Output Terminal
Connect TIG torch to electrode weld outout
terminal.
4
Work Weld Output Terminal
Connect work lead to work weld output terminal.
1
4
5
5
Remote 14 Receptacle
Connect desired remote control to Remote
14 receptacle (see Section 4-8).
6
Water-In (From Torch) Connection
Connect torch water-out (red) hose to
welding power source water-in connection.
Tools Needed:
7
11/16, (21 mm)
8
803 601-B
Gas−Out Connection
Connect torch gas hose to gas-out fitting.
Water-Out (To Torch) Connection
Connect torch water-in (blue) hose to welding power source water-out connection.
4-12. TIG Connections With A Two-Piece Air-Cooled Torch
Y 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 dispay, see Section
4-14. For TIG AC welding, place switch
in AC position (see Section 5-2). For
TIG AC front panel control dispay, see
Section 4-15.
6
5
3
3
Work Weld Output Terminal
Connect work lead to work weld output
terminal.
1
4
4
Remote 14 Receptacle
Connect desired remote control to Remote 14 receptacle (see Section 4-8).
5
11/16, (21 mm)
Tools Needed:
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-B
OM-362 Page 19
4-13. TIG Connections With A One-Piece Air-Cooled Torch
Y Turn Off power before making
connections.
1
Gas-In Connection
Connect gas hose from gas supply to
gas−in connection.
2
2
Switch is shown in DCEN (direct current electrode negative) position for
TIG HF Impulse DCEN welding. For
front panel control dispay, see Section
4-14. For TIG AC welding, place switch
in AC position (see Section 5-2). For
TIG AC front panel control dispay, see
Section 4-15.
6
5
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 4-8).
4
5
Tools Needed:
11/16, (21 mm)
803 615-A
OM-362 Page 20
Output Selector Switch (See
Section 5-2)
Electrode Weld Output Terminal
Connect TIG torch to electrode weld
output terminal.
6
Gas-Out Connection
Connect torch gas hose to gas-out
fitting.
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.
NOTE: Green on nameplate indicates a TIG function (see Section
5-1 for description of controls).
1
(CE Nameplate)
1
OM-362 Page 21
4-15. Front Panel Display For TIG AC
1
. For all front panel switch pad
Front Panel
Correct front panel display for
basic TIG AC welding.
controls: press switch pad to
turn on light and enable
function.
NOTE: Green on nameplate indicates a TIG function (see Section 5-1 for description of controls).
1
(CE Nameplate)
1
OM-362 Page 22
4-16. Stick Connections
Y 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 outout terminal.
3
Remote 14 Receptacle
If desired, connect remote control
to Remote 14 receptacle (see Section 4-8).
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 dispay, see Section
4-17. For Stick AC welding, place
switch in AC position. For Stick AC
front panel control dispay, see Section 4-18.
3
1
Tools Needed:
11/16, (21 mm), 3/4 in
803 587-A
OM-362 Page 23
4-17. Front Panel Display For Stick DCEP (Direct Current Electrode Positive)
1
. For all front panel switch pad
Front Panel
Correct front panel display for
basic Stick DCEP welding.
controls: press switch pad to
turn on light and enable
function.
NOTE: Gray on nameplate indicates a Stick function (see Section 5-1 for description of controls).
1
(CE Nameplate)
1
OM-362 Page 24
4-18. Front Panel Display For Stick AC
1
. For all front panel switch pad
Front Panel
Correct front panel display for
basic Stick AC welding.
controls: press switch pad to
turn on light and enable
function.
NOTE: Gray on nameplate indicates a Stick function (see Section 5-1 for description of controls).
1
(CE Nameplate)
1
OM-362 Page 25
4-19. Electrical Service Guide
NOTE
All values in both tables were calculated at 60% duty cycle.
NOTE
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.
50/60 Hertz Models
Without Power Factor Correction
Input Voltage
200
220
230
400
440
460
520
575
Input Amperes 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 AWG
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG
* Input amperes at rated output is the amperage draw for that particular input voltage if the machine is run at its rated welding
output (see Section 4-4 for rated welding output).
Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).
Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
50/60 Hertz Models
With Power Factor Correction
Input Voltage
200
220
230
400
440
460
520
575
Input Amperes At Rated Output*
60
61
52
34
31
26
26
21
Time-Delay Fuse 2
90
90
80
50
45
40
40
30
Normal Operating (Fast) Fuse 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
Min Input Conductor Size In AWG
Max Recommended Input Conductor Length In
Feet (Meters)
Min Grounding Conductor Size In AWG
* Input amperes at rated output is the amperage draw for that particular input voltage if the machine is run at its rated welding
output (see Section 4-4 for rated welding output).
Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a time-delay fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (fast) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above).
Y Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
OM-362 Page 26
4-20. Placing Jumper Links
Label found on models with the following stock numbers:
907194, 907194-021 and, 907194-031
2
200 VOLTS
230 VOLTS
460 VOLTS
Check input voltage available at
site.
1
1
L
L
L
L
L
L
Or
L
L
460 VOLTS
L
2
Jumper Links
Move jumper links to match input
voltage.
Label found on models with the following stock numbers:
907195, 907195-021 and, 907195-031
230 VOLTS
Jumper Link Label
Check label − only one label is on
unit.
S-083 566-E
1
Y Disconnect and lockout/tagout input power before
installing or moving jumper
links.
L
Close and secure access door, or
go on to Section 4-21.
575 VOLTS
L
L
S-010 587-D
Or
Label found on models with the following stock number 907197
1
Tools Needed:
3/8 in
Ref. 803 585-A
OM-362 Page 27
4-21. Connecting Input Power
1
8
=GND/PE Earth Ground
10
7
9
L1
L2
2
6
4
1
5
3
Tools Needed:
4
3/8 in
6
Ref. 803 585-A
Y Installation must meet all National and
Local Codes − have only qualified persons make this installation.
Y Disconnect and lockout/tagout input
power before connecting input conductors from unit.
Y Make input power connections to the
welding power source first.
Y 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 4-19. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
OM-362 Page 28
Welding Power Source Input Power Connections
2
Strain Relief
Route conductors (cord) through strain relief
and tighten screws.
3
Machine Grounding Terminal
4
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to welding power source grounding
terminal first.
5
Welding Power Source Line Terminals
6
Input Conductors L1 And L2
Connect input conductors L1 and L2 to welding power source line terminals.
Close and secure access door on welding
power source.
Disconnect Device Input Power Connections
7 Disconnect Device (switch shown in
OFF position)
8 Disconnect Device (Supply) Grounding
Terminal
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.
10 Overcurrent Protection
Select type and size of overcurrent protection
using Section 4-19 (fused disconnect switch
shown).
Close and secure door on line disconnect device. Remove lockout/tagout device, and
place switch in the On position.
SECTION 5 − OPERATION
5-1. Controls
A. For 200/230/460 Volts And Non CE Units
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.
8
NOTE: Meters are self-calibrating. No adjustment 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 A, the range of the remote amperage control is 5 to 200 A.
For pulse welding, use Amperage Adjust
control to select from 5−300 amps of peak
amperage (see Section 5-12).
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).
For spot welding, use Amperage Adjust
control to select from 5−310 amps (see Section 5-16).
10 Balance/DIG Control
Voltmeter displays average voltage (to the
nearest 0.1 V) at the weld output terminals.
7
11 Pulser Controls (Optional)
Use meter to preset amperage. Meter displays average weld amperage output of unit
to nearest ampere when welding.
8
5
Voltmeter And Ammeter
Output Selector Switch
See Section 5-2.
Power Switch
Use switch to turn unit Off and On.
See Section 5-10.
See Section 5-12.
12 Sequence Controls (Optional)
See Section 5-13.
217 264-A / 213 106-A
OM-362 Page 29
B. For CE Units
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.
8
NOTE: Meters are self-calibrating. No adjustment 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 A, the range of the remote amperage control is 5 to 200 A.
For pulse welding, use Amperage Adjust
control to select from 5−300 amps of peak
amperage (see Section 5-12).
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).
For spot welding, use Amperage Adjust
control to select from 5−310 amps (see Section 5-16).
10 Balance/DIG Control
Voltmeter displays average voltage (to the
nearest 0.1 V) at the weld output terminals.
7
11 Pulser Controls (Optional)
Use meter to preset amperage. Meter displays average weld amperage output of unit
to nearest ampere when welding.
8
5
Voltmeter And Ammeter
Output Selector Switch
See Section 5-2.
Power Switch
Use switch to turn unit Off and On.
See Section 5-10.
See Section 5-12.
12 Sequence Controls (Optional)
See Section 5-13.
215 460-A / 218 584-A
OM-362 Page 30
5-2. Output Selector Switch
1
Output Selector Switch
Y Do not use AC output in
damp areas, if movement is
confined, or if there is danger of falling. Use AC output
ONLY if required for the
welding process, and then
use a remote control.
Y Do not change position of
switch while welding or
while under load.
1
Use switch to select (DCEN) Direct
Current Electrode Negative, AC, or
(DCEP) Direct Current Electrode
Positive output.
NOTE: 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
(CE Nameplate)
Process Control
Use control to select Shielded Metal Arc Welding (SMAW) or Gas
Tungsten Arc Welding (GTAW) process.
For SMAW, press button to toggle
LED to Stick position.
For GTAW, press button to toggle
LED to TIG position.
NOTE: Lit LED indicates selected
mode.
1
1
When Output Selector switch position changes, LED may change
position, based upon last selection.
Ref. 217 264-A / Ref. 215 460-A
5-4. Amperage Control
1
(CE Nameplate)
Amperage Control
Use control to select front panel or
remote amperage control.
For front panel amperage control,
press button to toggle LED to Panel
position.
For remote amperage control,
press button to toggle LED to Remote position (see Section 4-8).
1
1
NOTE: Lit LED indicates selected
mode.
When Output Selector switch position changes, LED may change
position, based upon last selection.
OM-362 Page 31
5-5. Output Control
Remote (Standard)Torch Trigger Operation
(CE Nameplate)
2
2
1
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
1
Output Control
Release For
Maintained Switch
2
Remote Trigger (Standard) Operation
Release Foot Or
Finger Remote
Control
NOTE: If On/Off only type trigger is used,
it must be a maintained switch. All functions become active.
Y 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 4-8).
Use control to select front panel, trigger
hold, or remote output control.
Torch trigger operation is as shown.
Application: Use Remote Trigger when
the operator desires to use a foot pedal or
finger amperage control.
NOTE: 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.
NOTE: Lit LED indicates selected mode.
For weld output, press button to toggle LED
to On position.
OM-362 Page 32
Trigger Hold (2T)
(CE Nameplate)
3
Current (A)
3
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.
NOTE: 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.
NOTE: 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-362 Page 33
5-6. 4T, 4T Momentary, And Mini Logoic 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.
NOTE: 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.
NOTE: 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-362 Page 34
Push & Release
Trigger
Push & Release
Trigger
Push & Release
Trigger
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.
NOTE: 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-362 Page 35
5-7. Reconfiguring Trigger Hold For 4T And Mini Logic Control
1
2
Output Control
Power Switch
2
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].
Front Panel
Press Output control button to
change functions. Active function will
be displayed on amperage (bottom)
meter.
3
1
Meter Displays
Meter displays for the different functions will be as shown.
Press torch trigger or turn power Off
to save setting.
SEL
Proceed to Section 5-6 for 4T Operation.
Proceed to Section 5-6 for Mini Logic
operation.
H−2
Proceed to Section 5-6 for 4T Momentary operation.
NOTE: These features are only
available when optional Sequencer
is installed.
SEL
H-4E
= 4T Momentary
(See Section 5-6)
SEL
SEL
= Mini Logic (See Section 5-6)
= 4T (See Section 5-6)
H−4
H4L
3
OM-362 Page 36
2
(CE Nameplate)
Front Panel
1
SEL
H−2
SEL
H-4E
= 4T Momentary
(See Section 5-6)
SEL
SEL
= Mini Logic (See Section 5-6)
= 4T (See Section 5-6)
H−4
H4L
3
OM-362 Page 37
5-8. Selecting TIG Starting Characteristics
1
4
SEL
−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 op-
OM-362 Page 38
tions). Push and hold Start Mode button and
turn On power. Hold button for approximately
7 seconds (or until software version number_
_ _ _ _ _-_ clears meters).
The TIG LED and all four Start LEDs will light,
and the meters will display [SEL] [−2−].
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.
Press torch trigger or turn Off power to save
setting.
Application:
Select 1 (light/soft start) − when welding at
low amperages on thin gauge material.
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.
(CE Nameplate)
1
4
SEL
−2−
2
3
OM-362 Page 39
5-9. Start Mode
(CE Nameplate)
1
1
2
3
Lift-Arct Start Method
“Touch”
1−2
Seconds
Do NOT Strike Like A Match!
1
Start Mode
For SMAW welding, press button to toggle
LED to Off position.
For GTAW welding, use control to select
Off for no HF, Lift-Arct, 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:
2
TIG Electrode
3
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 sec-
OM-362 Page 40
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.
NOTE: 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
NOTE: Some start methods may not be
available for all processes.
5-10. Balance/DIG Control
1
(CE Nameplate)
Balance/DIG Control
Balance Control (AC GTAW):
Control changes the AC output
square wave. Rotating the control
towards 10 provides deeper penetration. Rotating the control towards
0 provides more cleaning action of
the workpiece.
1
1
When the control is in the Balanced
position, the wave shape provides
equal penetration and cleaning
action.
Application:
Balance Control Examples
Setting
Balanced
3
Output Waveforms
50% Electrode
Positive
50% Electrode
Negative
Max Penetration
10
Max Cleaning
0
32% Electrode
Positive
68% Electrode
Negative
55% Electrode
Positive
45% Electrode
Negative
Arc
When welding on oxide forming materials such as aluminum or magnesium, excess cleaning is not necessary. To produce a good weld, only
a minimal amount, approximately a
0.10 in (2.5mm) of etched zone
along the weld toes is required.
Set control to 3 and adjust as necessary. Joint configuration, set-up,
process variables, and oxide thickness may affect setting.
NOTE: Arc rectification can occur
when welding above 200 amps
and/or while welding with helium
gas. If this condition occurs, increasing the Balance control towards maximum penetration, may
help to restabilize the arc.
DIG Control (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:
Control helps arc starting or making
vertical, or overhead welds by increasing amperage at low arc voltage, and reduces electrode sticking
while welding.
Ref. S-0795-A
OM-362 Page 41
5-11. Preflow Time Control
1
4
00.4
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-362 Page 42
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).
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:
(CE Nameplate)
1
4
00.4
SEL
2
OM-362 Page 43
5-12. Pulse Controls (Optional)
1
4
3
2
1
On/Off Control
Use control to turn pulse function
On and Off.
2
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.
3
(CE Nameplate)
3
2
1
Pulse Frequency
Ranges from 0.25−10.0 pps
(pulses per second). Control is
used to determine appearance of
weld bead.
4
4
Peak Time
A range of 5−95% of each pulse
cycle can be spent at the peak amperage level.
Peak amperage (5−310 amps), 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.
5
5
Pulsed Output Waveforms
Example shows affect changing
the Peak Time control has on the
pulsed output waveform.
Application:
Percent (%) Peak
Time Control Setting
Pulsed Output Waveforms
PPS
(50%)
Bkg Amp
Balanced
Peak Amp
More Time
At Peak
Amperage
(80%)
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.
NOTE: Function is enabled, when
LED is lit.
More Time At
Background
Amperage
OM-362 Page 44
(20%)
5-13. Sequence Controls (Optional)
1
Initial Time Control
See Section 5-14.
2
Initial Amperage Control
See Section 5-14.
5
3
1
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
(CE Nameplate)
5
1
2
3
4
OM-362 Page 45
5-14. Initial Time Control And Initial Amperage Control
1
Initial Time Control
Indicator light is on when Initial
Time control function is active.
(CE Nameplate)
1
NOTE: 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.
NOTE: Initial Amperage control
function is inactive when Spot Time
function is active.
2
2
Use control to select a starting amperage (5−310 amps) that is different from the weld amperage. Note:
Initial Amperage can be used with
or without a remote control (Initial
Amperage and Initial Time control
settings will override a remote control device).
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.
NOTE: Function is enabled, when
LED is lit.
OM-362 Page 46
5-15. Final Slope Control And Final Amperage Control
1
Final Slope Control
Indicator light is on when Final Slope
control function is active.
(CE Nameplate)
Note: 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.
Note: 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
Note: This applies if the operator is
using an on/off only type control to
start and stop the welding process.
Note: Do not use this function with a
foot or finger amperage control.
NOTE: Function is enabled, when
LED is lit.
5-16. Spot Time Control
(CE Nameplate)
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).
1
Used with the (GTAW) TIG Spot process, generally with a direct current
electrode negative (DCEN) set-up.
Application:
Use control to select 0−15 seconds of
spot time.
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.
Use Amperage Adjust control (see Section 5-1) to set amperage.
NOTE: Function is enabled, when LED
is lit.
OM-362 Page 47
5-17. Timer/Cycle Counter
1 2 3
3
1
2
4 5 6
1 2 3
(CE Nameplate)
4
4 5 6
1
1 Amperage Control
2 Output Control (Contactor)
To read timer/cycle counter, hold Amperage and Output (contactor) buttons while
turning on power.
OM-362 Page 48
2
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.
5-18. Resetting Unit To Factory Default Settings (All Models)
1
2
3
4
5
(CE Nameplate)
1
2
3
4
5
1
2
3
4
Process Control
Amperage Control
Output Control
Start Control
5
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).
OM-362 Page 49
SECTION 6 − MAINTENANCE
6-1. Routine Welding Power Source Maintenance
Y Disconnect power before maintaining.
3 Months
Clean And
Tighten
Weld
Terminals
Repair Or
Replace
Cracked
Weld
Cables
Replace
Unreadable
Labels
Adjust Spark
Gaps
Replace
Cracked
Parts
14-Pin Cord
Gas Hose
Torch Cable
6 Months
Blow Out Or Vacuum Inside,
During Heavy Service, Clean Monthly
OR
Y Warranty is void if machine fails
due to contaminates inside.
6-2. Routine Cooler Maintenance
Y Disconnect power
before maintaining.
1 Month
Y 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.
Blow Out Heat
Exchanger Fins
6 Months
Replace
Cracked
Hoses
Change Coolant
(If Using Water)
see Section 4-10
Replace
Damaged Or
Unreadable
Labels
12 Months
Oil
Motor
OM-362 Page 50
Change Coolant (If Using MILLER
Coolant) see Section 4-10
6-3. Circuit Breaker CB1
Y Turn off power before resetting breaker.
1
Circuit Breaker CB1
If CB1 opens, high frequency and
output to the 115 volts ac duplex receptacle stop. Press button to reset
breaker.
1
Ref. 803 588-A
6-4. Adjusting Spark Gaps
Y Turn Off welding power
source and disconnect and
lockout/tagout input power
before adjusting spark gaps.
Remove right side panel..
2
1
1
Tungsten End Of Point
Replace point if tungsten end disappears; do not clean or dress
tungsten.
2
Spark Gap
Normal spark gap is 0.012 in (0.305
mm).
3
4
If adjustment is needed, proceed as
follows:
3
Adjustment Screws
Loosen screws. Place gauge of
proper thickness in spark gap.
4
Tools Needed:
0.012 in (0.305 mm)
803 592-A
3/8n
Pressure Point
Apply slight pressure at point until
gauge is held firmly in gap. Tighten
screws. Adjust other gap.
5/32 in
Reinstall right side panel.
OM-362 Page 51
SECTION 7 − TROUBLESHOOTING
7-1. Voltmeter/Ammeter Help Displays
. All directions are in reference to the front of the unit. All
1
V
1
• Help 7 Display
circuitry referred to is located inside the unit. There are
no user serviceable parts inside unit.
Not used.
Typical Help Display (For Help 0)
Not used.
• Help 8 Display
• Help 0 Display
• Help 9 Display
HLP
Short in the thermal protection circuitry. Contact a Factory
Authorized Service Agent.
Short in the thermal protection circuitry. Contact a Factory
Authorized Service Agent.
• Help1 Display
• Help 10 Display
A
An SCR overcurrent condition has occurred. Turn power
off and on. If condition continues, contact a Factory Authorized Service Agent.
−−0
• Help 11 Display
• Help 2 Display
Output Selector switch is not in correct position (see Section 5-2).
Malfunction in the thermal protection circuitry. Contact a
Factory Authorized Service Agent.
• Help 12 Display
• Help 3 Display
Non-allowable set-up of the front panel.
• Help 13 - 16 Displays
Transformer has overheated. The unit has shut down to allow the fan to cool unit (see Section 4-5). Operation will
continue when the unit has cooled.
Not used.
• Help 4 Display
Malfunction in the thermal protection circuitry of the cooler.
Contact a Factory Authorized Service Agent.
Malfunction in the thermal protection circuitry. Contact a
Factory Authorized Service Agent.
• Help 18 Display
• Help 5 Display
Rectifier assembly has overheated. The unit has shut
down to allow the fan to cool unit (see Section 4-5). Operation will continue when the unit has cooled.
• Help 6 Display
Not used.
OM-362 Page 52
Remote Output control is activated. Release Remote Output control.
• Help 17 Display
Coolant system coolant has overheated. The unit has shut
down to allow the coolant to cool (see Section 4-5). Operation will continue when the coolant has cooled.
• Help 19 Display
Indicates low coolant flow in the coolant system. The unit
output has shut down and will not start again until the coolant flow level is corrected, and the power is turned off and
back on.
7-2. Troubleshooting The Welding Power Source
NOTE: The remedies listed below are recommendations only. If these remedies do not fix
the trouble with your unit, have a Factory Authorized Service Agent check unit.
There are no user serviceable parts inside unit.
Refer to Section 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 4-21).
Check and replace line fuse(s), if necessary (see Section 4-21).
Check for proper input power connections (see Section 4-21).
Check for proper jumper link position (see Section 4-20).
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 4-7).
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 duplex receptacle RC2
and no high frequency.
Reset circuit breaker CB1 (see Section 6-3).
Lack of high frequency; difficulty in
starting GTAW arc.
Reset circuit breaker CB1 (see Section 6-3).
Select proper size tungsten.
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 6-4).
Wandering arc − poor control of
direction of arc.
Reduce gas flow rate.
Select proper size tungsten.
Properly prepare tungsten.
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.
Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to
protect against overheating.
OM-362 Page 53
7-3. Troubleshooting The Welding Coolant System
NOTE: The remedies listed below are recommendations only. If these remedies do not fix
the trouble with your unit, have a Factory Authorized Service Agent check unit.
There are no user serviceable parts inside unit.
Refer to Section 7-1 for any Help (HLP) message displayed on voltmeter/ammeter.
Trouble
Coolant system does not work.
Remedy
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 (see Section 4-10).
Check for clogged hoses or coolant filter.
Disconnect pump, and check for sheared coupling. Replace coupling if necessary.
Decreased cooling ability; coolant too
hot.
Clean heat exchanger fins and blower assembly (see Section 6-2).
Foaming Coolant
Check for cracked or loose hoses or loose covers on filter or flowmeter, and tighten or replace.
Check for loose cap or bad seal on filter assembly, and tighten or replace as necessary.
Flow Indicator not turning
OM-362 Page 54
Check circulation, and/or remove and clean indicator and housing.
SECTION 8 − ELECTRICAL DIAGRAM
Figure 8-1. Circuit Diagram All Models
215 704-A
OM-362 Page 55
SECTION 9 − HIGH FREQUENCY
9-1. 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 12/96 − S-0693
9-2. Incorrect Installation
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
5
6
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
OM-362 Page 56
9-3. Correct Installation
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece
if required
by codes.
9
Metal Building
8
8
11
10
Ref. S-0695 / Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
8
11 Overhead Door Track
Grounding Rod
Consult the National Electrical Code for
specifications.
Ground the track.
OM-362 Page 57
SECTION 10 − SELECTING AND PREPARING TUNGSTEN
ELECTRODE FOR DC OR AC WELDING
ac/dc_gtaw 2/2000
Y Whenever possible and practical, use DC weld output instead of AC weld output.
10-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
65% Electrode Negative
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens
.040” (1 mm)
25-85
20-80
1/16” (1.6 mm)
50-160
50-150
3/32” (2.4 mm)
135-235
130-250
1/8” (3.2 mm)
250-400
225-360
Pure Tungsten (Green Band)
.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.
10-2. Preparing Tungsten Electrode For Welding
Y Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines
2-1/2 Times
Electrode Diameter
Radial Grinding
Causes Wandering Arc
1
3
2
1
2
3
4
Wrong Tungsten Preparation
Ideal Tungsten Preparation − Stable Arc
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.
Tungsten Electrode
Flat
Diameter of this flat determines amperage
capacity.
4
Straight Ground
Grind lengthwise, not radial.
B. Preparing Tungsten For Conventional AC Welding
1 − 1-1/2 Times
Electrode Diameter
1
Temporary OM-362 Page 58
2
1
2
Tungsten Electrode
Balled End
Ball end of tungsten by applying AC amperage recommended for a given electrode
diameter (see Section 10-1). Let ball on end
of the tungsten take its own shape.
Notes
OM-362 Page 59
SECTION 11 − PARTS LIST
. Hardware is common and
not available unless listed.
106
4
107
68
55
66
108
63
105
70
16
23
103
91
20
89
17
12
104
14
15
49
104
29
40
21
22
19
48
18
28
Figure 11-1. Main Assembly
OM-362 Page 60
45
41
87
104
43
64
65
44
59
54
39
11
34
33
37
42
38
96
35
95
97
83
104
3
5
7
8
46
6
10
13
90
52
9
78
53
80
75
1
73
58
2
82
76
104
78
72
97
803 774-A
OM-362 Page 61
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
. . . 1 . . . . . . . . . . . 211038
. . . 2 . . . . . . . . . . 215656
. . . 3 . . T1/Z1 . 212555
. . . 3 . . T1/Z1 . . 211041
. . . 3 . . T1/Z1 . 219652
. . . 4 . . . . . . . . . . 212550
. . . 5 . . . TE1 . . 218175
. . . 6 . . . . . . . . . . 213248
. . . 7 . . C5, 6 . . 111634
. . . 8 . . . SR1 . . 212558
. . . 9 . . . . . . . . . . 218670
. . . 10 . . . . . . . . . . 212559
. . . 11 . . . . R3 . . 218173
. . . 12 . . . . S5 . . 215390
. . . 13 . . . . . . . . . +213105
. . . 14 . . . . S1 . . 215937
. . . 15 . . . . . . . . . . . 213114
. . . . . . . . . . . . . . . . . 117860
. . . . . . . . . . . . . . . . 107983
. . . . . . . . . . . . . . . . 143397
. . . 16 . . . PC1 . . 209877
. . . 18 . . . . . . . . . . 183332
. . . 19 . . . . . . . . . . 174991
. . . 20 . . . . . . . . . . 195778
. . . 21 . . . . . . Figure 11-2
. . . 22 . . . C14 . . 209587
. . . 23 . . . PC2♦♦195 344
. . . 25 . . . . . . . . . . 217264
. . . 25 . . . . . . . . . . 215460
. . . 26 . . . . . . . . . . 213106
. . . 26 . . . . . . . . . . 218584
. . . 28 . . . . . . . . . . 175952
. . . 29 . . . . . . . . . . 215685
. . . 33 . . . . . . . . . . 212548
. . . 34 . . . . . . . . . . 184058
. . . 35 . . . . . . . . . . 187807
. . . 37 . . . . . . . . . . 150783
. . . 38 . . FM1, 2 220393
. . . 39 . . . . 1T . . 199312
. . . 40 . . . GS1 . . 215776
. . . 41 . . . . . . . . . . 208408
. . . . . . . . . . . . . . . . . 217111
. . . 42 . . . . . . . . . . 204293
. . . 43 . . . . . . . . . . 168343
. . . 44 . . . . . . . . . +215657
. . . 45 . . . . . . . . . . 189491
. . . 46 . . . . . . . . . . 217553
. . . 48 . . . . T4 . . 215771
. . . 49 . . . . . . . . . . 207560
. . . 52 . . . . . . . . . ♣211043
. . . 53 . . . . . . . . . . 199479
. . . 54 . . . . . . . . . . 026627
. . . 55 . . . . . . . . . +211040
. . . 58 . . . . . . . . . . 208294
. . . 59 . . . . . . . . . . 010467
. . . 63 . . . . . . . . . . 203990
. . . 64 . . . . . . . . . . 127363
. . . 65 . . . . . . . . . . 168384
. . . 66 . . . . . . . . . . 201019
OM-362 Page 62
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BASE,ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
END CAP, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR/STABILIZER ASSY, 200/230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR/STABILIZER ASSY, 230/460/575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
XFMR/STABILIZER ASSY, 220/400/440/520 . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,LEFT WINDTUNNEL (for non-TIGRUNNER models) . . . . . . . . . . . . .
TERM ASSY,PRI 1PH 3V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUG,UNIV W/SCREW 2/0−14 WIRE .266STD . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECTIFIER,SCR MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,RECTIFIER RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,RECTIFIER LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR,WW FXD 400 W 35 OHM W/MTG BKT . . . . . . . . . . . . . . . . . . . . .
SWITCH ASSY,POLARITY W/LEADS & HARDWARE (DX) . . . . . . . . . . . . . .
PANEL,RIGHT WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH,TGL ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT PANEL ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLANK,SNAP−IN NYL .187 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . .
BLANK,SNAP−IN NYL .500 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . .
BLANK,SNAP−IN NYL .312 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY,CONTROL & INTERFACE W/PROGRAM . . . . . . . . .
KNOB,POINTER .570 DIA X .125 ID W/SPRING CLIP . . . . . . . . . . . . . . . . . .
KNOB,POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . . . . .
ACTUATOR PUSH BUTTON ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,LOWER DINSE CONN ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PULSER OPTION, SYNCROWAVE 250 DX (FIELD) . . . . . . . . . . . . . . . . . . . .
NAMEPLATE,MILLER SYNCROWAVE DX (UPPER) WORD&SYMBOL . . .
NAMEPLATE,MILLER SYNCROWAVE DX (UPPER) CE WORDLESS . . . . .
NAMEPLATE,MILLER SYNCROWAVE DX (LOWER) . . . . . . . . . . . . . . . . . . . .
NAMEPLATE,MILLER SYNCROWAVE DX (LOWER) CE . . . . . . . . . . . . . . . .
PLASTIC,HANDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN,PLENUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET,MTG MOTOR FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLADE,FAN 9.000 5WG 39DEG .312 BORE CW PLSTC . . . . . . . . . . . . . . . .
MOTOR,FAN 230V 50/60HZ 1550 RPM .312 DIA SHAFT . . . . . . . . . . . . . . . .
BLOCK,TERMINAL FAST−ON,20 AMP,250 VOLT . . . . . . . . . . . . . . . . . . . . . .
VALVE, 24VDC 2WAY CUSTOM PORT 1/8 ORF W/FRICT . . . . . . . . . . . . . . .
FTG,BRS BARBED FEM 1/4 TBG X .625−18 FLANGE MTG . . . . . . . . . . . . .
PLUG,PROTECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPORT,LIFT EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HINGE,CONT POLYOLEFIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR,ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPACER,HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,GROUND/PROTECTIVE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL,HF COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR,STANDOFF WITH STUD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL,SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,MILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKET,LIFTING EYE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER,TOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR,FASTON MALE 4−PRONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONN,CLAMP CABLE 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING GENERAL PRECAUTIONARY STATIC . . . . . . . . . . . . . . .
LABEL,WARNING ELECTRIC SHOCK CAN KILL . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING ELECTRIC SHOCK AND INCORRECT INPUT P . . . . . .
LABEL,WARNING ELECTRIC SHOCK EXCESS WEIGHT . . . . . . . . . . . . . . .
1
4
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
2
1
8
1
1
1
8
2
1
1
1
1
1
1
1
1
1
3
3
1
2
2
2
2
1
1
1
1
1
2
2
1
2
2
1
2
1
1
1
1
2
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (continued)
. . . 68 . . . . . . . . . ♣204389
. . . 70 . . . . . . . . . . 212557
. . . . . . . . . . . . . . . . . 213111
. . . . . . . . . . . . . . . . . 213112
. . . . . . . . . . . . . . . . . 213112
. . . 72 . . . . T3 . . 208045
. . . 73 . . . . G1 . . 199854
. . . . . . . . . . . . . . . . 199855
. . . . . . . . . . . . . . . . 199856
. . . . . . . . . . . . . . . . 196455
. . . 75 . . . . R8 . . 188067
. . . 76 . . . . C3 . . 215779
. . . 78 . C11, 19 195552
. . . 80 . . . . R1 . . 220808
. . . 82 . . . C13 . . 206878
. . . 83 . . . . . . . . . . 216081
. . . 87 . . . . . . . . . . 218170
. . . 89 . . . . . . . . . . . 211039
. . . 90 . . . . . . . . . . 192828
. . . 91 . . . HD2 . . 191941
. . . 95 . . . . C2 . . 031668
. . . 96 . . . . . . . . . . 108105
. . . 97 . . R2, 4 . . 118459
. . 103 . . PC3♦♦195345
. . 104 . . . . ♦Figure 11-4
. . 105 . . . . ♦Figure 11-3
. . 106 . . . . . . . . ♦212556
. . 107 . . . . . . ♦211037
. . 108 . . CR1 . ♦059266
. . . . . . . . . . . . . . . ♦194744
. . HOLDER,TORCH/CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DRAWER,ASSY (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DRAWER,PLASTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . DRAWER,FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SLIDE, DRAWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . XFMR,HIGH VOLTAGE 115V PRI 3600V SEC 30 MA W/TERM . . . . . . . . . . .
. . SPARK GAP ASSY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOLDER, POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . POINTS, SPARK GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR,WW FXD 100 W 200 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR,MICA .002 UF 10000 V PANEL MTG W/LEA . . . . . . . . . . . . . . .
. . CAPACITOR,POLYP MET FILM 20. UF 250 VAC 10% . . . . . . . . . . . . . . . . . . .
. . RESISTOR,WW FXD 100 W 50 OHM W/CLIPS . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET,RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE,NPRN BRD NO 1 X .250 ID X 24.000 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BEZEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL,WARNING ELECTRICAL SHOCK ETC . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSDUCER,CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR,ELCTLT 4000 UF 100 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP,CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR,WW FXD 10 W 1K OHM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEQUENCE MODULE, (FIELD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TIGRUNNER RUNNING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ASSY, COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL,SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLDER, COOLANT FILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY,ENCL 120VAC DPDT 10A/120VAC 8PIN . . . . . . . . . . . . . . . . . . . . . . . .
. . RFCS−14HD (FOOT CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1
1
1
2
1
2
1
4
4
1
1
2
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Included with TIGRUNNER option.
♦♦Field option only.
♣For TIGRUNNER models, the quantity is 1.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-362 Page 63
. Hardware is common and
12
not available unless listed.
11
10
3
12
10
11
5
14
9
1
13
8
14
9
2
13
8
803 775-A
Figure 11-2. Panel, Lower Dinse Connector Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
217 110
...
...
...
...
...
...
...
...
...
...
...
1
2
3
5
8
9
10
11
12
13
14
. . . . . . . . . . 213109
. . . . . . . . . . 215778
. . . . . . . . . . . 211911
. . . . . . . . . . 218174
. . . . . . . . . . 202553
. . . . . . . . . . 185712
. . . . . . . . . . 185713
. . . . . . . . . . 185714
. . . . . . . . . . 185717
. . . . . . . . . . 186228
. . . . . . . . . . 185718
..
..
..
..
..
..
..
..
..
..
..
Quantity
Figure 11-2. Panel, Lower Dinse Connector Assy (Figure 11-1 Item 21)
PANEL,LOWER DINSE CONN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LABEL,COMPONENT IDENTIFICATION CE WORDLESS . . . . . . . . . . . . . . .
CONN,CIRC MS/CPC 14SKT SIZE 20 RCPT W/FILTERING . . . . . . . . . . . . .
RECEPTACLE,W/LEADS & CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . .
RECEPTACLE,TWIST LOCK BRASS POWER (FEMALE) . . . . . . . . . . . . . . .
INSULATOR,BULKHEAD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSULATOR,BULKHEAD REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER,TOOTH 22MMID X 31.5MMOD 1.310−1MMT INTERN . . . . . . . . .
NUT,M20−1.5 1.00HEX .19H BRS LOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−RING, 0.739 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−RING, 0.989 ID X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
2
2
2
2
2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-362 Page 64
. Hardware is common and
15
20
not available unless listed.
2
20
3 20
5
21 20
6
20
20
19
18
17
4
19
20
12
13
1
20
20
14
9
20
10
20
8
5
20
16
803 779-A
Figure 11-3. Optional Cooler Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
212 544
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
8
9
10
12
13
14
15
16
17
18
19
20
21
. . . . . . . . . . . 211036
. . . . . . . . . . 215667
. . . . . . . . . . 215669
. . . . . . . . . . 215688
. . . . . . . . . . 215675
. . . . . . . . . . 215679
. . . . . . . . . . 217173
. . . . . . . . . . . 211042
. . . . . . . . . . . 211045
. . . . . . . . . . 215682
. . . . . . . . . . 215683
. . . . . . . . . . 215686
. . . . . . . . . . 166608
. . . . . . . . . . 220921
. . . . . . . . . . 215690
. . . . . . . . . . . . . 5523
. . . . . . . . . . 126978
. . . . . . . . . . 176746
. . . . . . . . . . 215673
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Quantity
Figure 11-3. Cooler Assy (Optional) (Figure 11-1 Item 105)
TANK,COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILTER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE,RUBBER BRAIDED 3/8 ID X 1/2 OD X 2 IN . . . . . . . . . . . . . . . . . . . . . .
FITTING,MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE,RUBBER BRAIDED 3/8 ID X 5/8 OD X 19 IN . . . . . . . . . . . . . . . . . . . . .
SWITCH,PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR,HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN,AC 230V BRUSHLESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP,COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE,RUBBER BRAIDED 3/8 ID X 1/2 OD X 8 1/2 IN . . . . . . . . . . . . . . . . . .
HOSE,RUBBER BRAIDED 3/8 ID X 1/2 OD X 16 IN . . . . . . . . . . . . . . . . . . . . .
VALVE,CHECK BIDIRECTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAP,TANK SCREW−ON W/VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE,CHECK BIDIRECTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE,RUBBER BRAIDED 3/8 ID X 1/2 OD X 4 1/2 IN . . . . . . . . . . . . . . . . . .
FTG,HOSE BRS BARBED ELBOW M 3/8 TBG X 3/8 NPT . . . . . . . . . . . . . . .
FTG,BRS BARBED M 3/8 TBG X 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP,1−EAR TYPE NOM DIM .656 X .275 WIDE . . . . . . . . . . . . . . . . . . . . .
FITTING, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
12
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-362 Page 65
. Hardware is common and
4
not available unless listed.
3
2
1
11
5
8
6
7
10
9
Ref. 803 725-A
Figure 11-4. Optional Running Gear
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Running Gear (Optional) (Figure 11-1 Item 104)
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
. . . . . . . . . . 218134
. . . . . . . . . . 215928
. . . . . . . . . . 168663
. . . . . . . . . . 602387
. . . . . . . . . . . 191158
. . . . . . . . . . 121614
. . . . . . . . . . 163463
. . . . . . . . . . . 191167
. . . . . . . . . . 168247
. . . . . . . . . . . 191163
. . . . . . . . . . 218135
..
..
..
..
..
..
..
..
..
..
..
HANDLE, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOTTLE SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOOK SPRING SNAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOTTLE TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CASTER, SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CASTER MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANDLE, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-362 Page 66
Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 6/04
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 2002 Miller Electric Mfg. Co.
5/02